Kawasaki Z1000SX - Service manual > Clean Air System

Air Suction Valve Removal

• Remove:
  Lower Fairing (see Lower Fairing Removal in the Frame chapter)
  Air Switching Valve (see Air Switching Valve Removal)
  Stick Coil Connector (see Stick Coil Removal in the Electrical System chapter)
  Connector [A] (from Bracket [B] at Left Side)
  Air Suction Valve Cover Bolts [C] and Bracket
  Air Suction Valve Covers [D] (Both Sides)

• Remove the air suction valves [A] on both sides.

Air Suction Valve Installation

• Install the air suction valve so that opening [A] of the reed faces the front and downward.

• Install the bracket [A] as shown in the figure.
• Apply a non-permanent locking agent to the threads of the air suction valve cover bolts [B], and tighten them.

  Torque - Air Suction Valve Cover Bolts: 9.8 N*m (1.0 kgf*m, 87 in*lb)

Air Suction Valve Inspection

• Remove the air suction valve (see Air Suction Valve Removal).
• Visually inspect the reeds [A] for cracks, folds, warps, heat damage or other damage.

  If there is any doubt as to the condition of the reeds, replace the air suction valve as an assembly.

• Check the reed contact areas [B] of the valve holder for grooves, scratches, any signs of separation from the holder or heat damage.

  If there is any doubt as to the condition of the reed contact areas, replace the air suction valve as an assembly.

  If any carbon or other foreign particles have accumulated between the reed and the reed contact area, wash the valve assembly clean with a high-flash point solvent.

NOTICE Do not scrape off the deposits with a scraper as this could damage the rubber, requiring replacement of the suction valve assembly.

Air Switching Valve Removal

NOTICE Never drop the air switching valve especially on a hard surface. Such a shock to the air switching valve can damaged it.

• Remove the stick coils (see Stick Coil Removal in the Electrical System chapter).
• Disconnect the connector [A].
• Clear the harness [B] from the clamp [C].
• Separate the hoses [D] from the air switching valve [E] to remove the air switching valve.

Air Switching Valve Installation

• Install the air switching valve [A] as shown in the figure.

  [B] Viewed Left Side
  [C] About 40º

Air Switching Valve Operation Test

• Refer to the Air Suction System Damage Inspection in the Periodic Maintenance chapter.

Air Switching Valve Unit Test

• Refer to the Air Switching Valve Unit Test in the Electrical System chapter.

Clean Air System Hose Inspection

• Be certain that all the hoses are routed without being flattened or kinked, and are connected correctly to the air cleaner housing, air switching valve and air suction valve covers.

  If they are not, correct them. Replace them if they are damaged.

See also: