Kawasaki Z1000SX - Service manual > Troubleshooting Guide

 Kawasaki Z1000SX - Service manual > Cable, Wire, and Hose Routing

Headlight Lead Run the brake hose to the rear side of the headlight lead. Brake Hose  Run the front right turn signal light lead through the air switching valve. And run to the rear side of the light switch housing. Air Switching Valve Clamp Air Switching Valve Air Switching Valve Hose Run the air switching valve hose to the upside of the stick coil lead. Stick Coil Lead Run the injector lead to the front side of the breather hose. Injector Lead Breather Hose Hold the injector lead with clamp Run the intake air temperature sensor to the upside of the crankshaft sensor lead. Intake Air Temperature Sensor Lead Crankshaft Sensor Lead Connect the horn lead connectors so that the horn lead comes upside. Insert the clamp on the main harness to the rib of the frame as shown. Run the headlight lead, right and left light switch housing lead, ignition switch lead, immobilizer amplifier lead (equipped models) and radiator fan motor lead to the front side of engine mount bracket, right turn signal light lead and air switching valve, and run them under the throttle cable and outside of frame. Left Switch Housing Lead Ignition Switch Lead Throttle Cables Right Switch Housing Lead Immobilizer Amplifier Lead Headlight Lead Run the clutch cable under the other lead and front side of radiator. Run the main harness to the outside of the between engine mount bracket and frame. Run the radiator fan motor lead, right switch housing and throttle cable in order from the frame. Radiator Fan Motor Lead Run the starter motor cable (+) to the upside of the battery negative (-) cable. Run the frame ground lead to the front side of the starter motor cable and battery negative (-) cable. Run the alternator lead to the under the main harness. Alternator Lead Run the alternator lead and crankshaft sensor lead to the rear side of breather hose. Main Harness Hold the alternator lead and crankshaft sensor lead with clamp. Battery Negative (-) Cable Starter Motor (+) Cable Frame Ground Lead Crankshaft Sensor Lead Run the fuel pump lead to the upside of the exhaust butterfly valve cables, to the outside of the fuse box, and to under the fuel tank bracket. Run the rear of main harness to inside of the battery case, to underside of the fuel pump lead, to rear of the battery case mounting and to the outside of the battery case as shown. Hold the fuel pump lead (main harness side) with the clamp. Hold the main harness with the clamp. Run the regulator/rectifier harness to the under the battery case. Run the starter motor cable to the upside of the main harness. Run the starter motor cable to between the main relay and battery, and to inside of the starter motor cable. Run the oxygen sensor lead (equipped models), crankshaft sensor lead and rear brake light switch lead to the outside of main harness. Crankshaft Sensor Lead Hold the rear brake light switch connector with the clamp. Rear Brake Light Switch Lead Oxygen Sensor Lead Main Harness Insert the clamps to the ribs of the inside of the frame, hold the oxygen sensor lead and crankshaft sensor lead. Run the regulator/rectifier harness from the cutout on the battery case to under side of the battery case. Regulator/Rectifier Harness Kawasaki Diagnostic System Connector ABS Self-diagnosis Connector (ABS Equipped Models) Relay Box Rear Left Turn Signal Light Lead Rear Right Turn Signal Light Lead ECU Run the leads to forward of the rear fender wall connect them. Run the turn signal light leads to the inside of ECU rib under the ECU and connect them. Run the right and left turn signal light leads to forward of the rear frame wall and connect them. Run the seat lock cable to front side of the frame wall and upside of the turn signal light lead and license plate light lead. Rear Left and Right Turn Signal Light Lead Run the license plate light lead to right side of the frame and connect them at position as shown. Tail/Brake Light (LED) Lead Run the licence plate light lead and tail/brake light (LED) lead reward to under of the rear frame after connected. Be careful not to pinch the leads with rear fender. License Plate Light Lead Run the licence plate light lead (main harness side) and tail/brake light (LED) lead (main harness side) reward to under of the rear flame (for prevention to pinch the leads with rear fender). Throttle Cable (Accelerator) Throttle Cable (Decelerator) Right Switch Housing Lead Brake Hose Clamp the brake hose, throttle cable (decelerator), throttle cable (accelerator) and right switch housing lead in order from the outside of frame. Run the brake hose comes to the most front side of the other lead. Run the right switch housing lead comes to the most rear side of the other lead. Front Right Turn Signal Light Lead Run the throttle cables, clutch cable, front turn signal light lead, right switch housing leads through this point to the inside of the frame. Clutch Cable Run the throttle cables and right switch housing leads through the inside of front fork. Clamp Run the exhaust butterfly valve cables to inside of the main harness. Exhaust Butterfly Valve Close Cable Exhaust Butterfly Valve Open Cable Main Harness Bend the clamp upward to secure the harness at the portion of the taped. Install the main harness clamp at the headlight bracket. Bend the clamp reward to inside to secure the harness at the portion of the taped. Main Harness Clamp Run the clutch cable and left switch housing lead in order from the inside of clamp. Clamp Run the left switch housing leads, ignition switch lead, immobilizer antenna lead (equipped models), and clutch cables to the inside of the front fork. Immobilizer Antenna Lead Clutch Cable Left Switch Housing Lead Ignition Switch Lead Run the ignition switch lead and immobilizer antenna lead inside of clamp. Clamp Run the clutch cable outside through the lower side of the radiator mounting position, and to the under of the other leads. Clamp Run the ignition switch lead, immobilizer antenna lead and left switch housing lead to the inside of the clamp. Insert the hole on the engine top heat protector into the slit on the radiator side pad. Connect the left turn signal light lead at the rear of radiator side pad, and push its connector into the cutout on the pad. Band Cover the right switch housing lead, ignition switch lead, immobilizer antenna lead (equipped models) and radiator fan motor lead with the rubber cover, and tie the rubber cover and main harness and neutral switch/oil pressure switch with the band then secure them to the heat insulation plate. Cut the band excess length after tying them. Main Harness Neutral Switch/Oil Pressure Switch Lead Ignition Switch Lead Right Switch Housing Lad Radiator Fan Motor Lead Rubber Cover Immobilizer Antenna Lead Hold the engine top heat protector to the heat insulation plate with the rivets from the front side (the right side is same as the left side). Heat Insulator Run the neutral switch/oil pressure switch lead to inside of rubber cover and connect them. Then hold the neutral switch/oil pressure switch lead with clamp on the engine bracket. Clamp Hold the neutral switch/oil pressure switch lead with clamp on the bracket. Air Cleaner Drain Hose Neutral Switch/Oil Pressure Switch Lead Idle Adjusting Screw Run the starter motor cable to the upside of the idle adjusting screw. Sidestand Switch Lead Speed Sensor Lead Fuel Tank Breather Hose (other than CAL and SEA-B1 models) Fuel Tank Drain Hose Starter Motor Cable Run the alternator lead to the outside of air cleaner drain hose and inside of neutral switch/oil pressure switch lead. Run the speed sensor lead and sidestand switch lead to the inside of the breather hose and fuel tank drain hose (other than CAL and SEA-B1 models). Run the end of fuel tank drain hose is as shown. Hold the sidestand switch lead with the clamp. Clamp Alternator Lead Air Cleaner Drain Hose Idle Adjusting Screw Run the idle adjusting screw to the under of the starter motor cable, outside of the air cleaner drain hose. Starter Motor Cable Run the fuel hose, starter motor cable, and alternator lead in order from the inside of the frame. Fuel Hose Alternator Lead Fuel Tank Drain Hose Sidestand Switch Lead Fuel Tank Breather Hose (other than CAL and SEA-B1 Models) Run the fuel tank breather hose (other than CAL and SEA-B1 models), sidestand switch lead and fuel tank drain hose to the inside of the chain cover. Air Cleaner Housing Air Switching Valve Hose Air Switching Valve Tighten the clamp bolt from left side. Tighten the clamp bolt from right side. Intake Air Temperature Sensor Install the clamp so that knob of the clamp faces rear side of the frame as shown. Breather Hose Clamp Clamps Air Cleaner Drain Hose Catch Tank White Paint Mark Right Left Viewed from A Insert the subharness connector to the clamp on the air suction valve cover. Run the subharness under the hose. Hose Subharness Run the subharness between the #1 and #2 throttle body holders so as not to pinch the lead with the throttle body assy. Install the clamp as shown in the direction. Water Hose Starter Motor Cable Viewed from B Water Temperature Sensor Lead Hold the neutral switch/oil pressure switch lead with the clamp at the upside of the separate pipe of the water pipe. Run the neutral switch/oil pressure switch lead with the clamp at the rear side of the separate pipe of the water pipe. Connect the neutral switch lead to the neutral switch. Do not stretch the lead after connected. Run the oil pressure switch lead to the inside of the water pipe. Cover the oil pressure switch with the switch cover. Hold the crankshaft sensor lead with the clamp. Crankshaft Sensor Lead Water pipe Run the alternator lead between the crankcase and water pipe. Viewed from A Regulator/Rectifier Harness Hold the regulator/rectifier harness with clamp. Rear Brake Light Switch Lead Exhaust Butterfly Valve Open Cable Exhaust Butterfly Valve Close Cable Oxygen Sensor Lead (Equipped Models) Run the rear brake light switch lead through the clamp to outside of exhaust butterfly valve cables. Run the exhaust butterfly valve open cable and close cable through the clamp in order from the front. Clamp (for Exhaust Butterfly Valve Cables) Clamp (for Oxygen Sensor Lead and Crankshaft Sensor Lead) Bend the clamp reaward to secure the oxygen sensor lead and crankshaft sensor lead. Crankshaft Sensor Lead Clamp (for Exhaust Butterfly Valve Cable) Run the exhaust butterfly valve open cable and close cable through the clamp in order from the front. Install the clamps as shown in the direction. Reserve Tank Hose Radiator Hose Water Hose Water Hose Reserve Tank Reserve Tank Overflow Hose Thermostat Radiator Radiator Hose Water Pipe Oil Cooler Water Hose Water Hose Water Pipe Water Hose Install the clamps so that its opening facing the direction indicated with arrow. Clamp (for Water Hose) Clamp (for Radiator Hose) Hold the clutch cable with clamp. Run the front right turn signal light lead to the upside of the reserve tank overflow hose. Front Turn Signal Light Lead Reserve Tank Overflow Hose Clamp (for Clutch Cable) Clutch Cable Viewed From A About 45º Viewed From B About 90º Run the reserve tank overflow hose to the inside of the frame. Reserve Tank Overflow Hose Run the water hose, reserve tank overflow hose, water hose in order the outside of frame. Water Hose Water Hose Connect the right turn signal light lead at the rear of radiator side pad, and push its connector into the cutout on the pad. Right Turn Signal Light Lead Run the reserve tank overflow hose to behind of the adjusting bolt, and between the adjusting bolt and frame, and directs it to underside of the frame. Hold the oxygen sensor lead (equipped models) and crankshaft sensor lead with clamp. Oxygen Sensor Lead Crankshaft Sensor Lead Run the clutch cable to front of engine bracket through the clamp on the front of the crankshaft sensor cover and inside of upper radiator hose. Clutch Cable Radiator Hose Install the clamps as shown, noting its screw head direction. White Paint Mark (Install the water hose so that the white paint mark faces upside of the engine.) Water Hose White Paint Mark (Install the water hose so that the white paint mark faces outside of the engine.) Water Hose Straight Side Install the radiator hose until the rised portion of the water pipe. Curve Side Viewed from A Install the clamp so that the tab of the clamp faces rear side of the engine. Install the clamp at the thermostat housing so that the tab of the clamp faces rear side of the engine. Viewed from B Breather Hose Water Hose White Paint Mark Install the clamp so that the tab of the clamp faces right side of the engine. Water Hose White Paint Mark (Install the water hose and water pipe so that the white paint mark faces outside of the engine.)

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