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Quick Reference Guide General Information 1 j PeriodicMaintenance 2 j FuelSystem (DFI) 3 j Cooling System 4 j Engine Top End 5 j Clutch 6 j Engine Lubrication System 7 j EngineRemoval/Installation 8 j Crankshaft/Transmission 9 j Wheels/Tires 10 j Final Drive 11 j Brakes 12 j Suspension 13 j Steering 14 j Frame 15 j Electrical System 16 j Appendix 17 j This quick reference guide will assist you in locating a desired topic or pro- cedure. •Bend the pages back to match the black tab of the desired
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Z750 All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Department/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as com
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LIST OF ABBREVIATIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) ATDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch °C degree(s) Celsius r revolution DC direct current rpm revolution(s) per minute F farad(s) TDC top dead center °F degree(s) Fahrenheit TIR total indicator reading ft foot, feet V volt(s) g gram(s) W
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Foreword This manual is designed primarily for use by trainedmechanicsinaproperlyequippedshop. How to Use This Manual However,itcontainsenoughdetailandbasicin- Inpreparingthismanual,wedividedtheprod- formationtomakeitusefultotheownerwhode- uct into its major systems. These systems be- sirestoperformhisownbasicmaintenanceand came the manual’s chapters. All information repair work. A basic knowledge of mechanics, foraparticularsystemfromadjustmentthrough the proper use of tools, and workshop proce
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NOTE This note symbol indicates points of par- ○ ticular interest for more efficient and con- venient operation. Indicates a procedural step or work to be • done. Indicates a procedural sub-step or how to do ○ the work of the procedural step it follows. It also precedes the text of a NOTE. Indicates a conditional step or what action to takebasedontheresultsofthetestorinspec- tion in the procedural step or sub-step it fol- lows. In most chapters an exploded view illustration of the system compone
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GENERAL INFORMATION 1-1 General Information 1 Table of Contents Before Servicing..................................................................................................................... 1-2 Model Identification................................................................................................................. 1-7 General Specifications............................................................................................................ 1-8 Technical Information – A
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1-2 GENERAL INFORMATION Before Servicing Before starting to perform an inspection service or carry out a disassembly and reassembly opera- tiononamotorcycle, readtheprecautionsgivenbelow. Tofacilitateactualoperations, notes, illustra- tions,photographs,cautions,anddetaileddescriptionshavebeenincludedineachchapterwherever necessary. This section explains the items that require particular attention during the removal and reinstallation or disassembly and reassembly of general parts. Especially not
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GENERAL INFORMATION 1-3 Before Servicing Arrangement and Cleaning of Removed Parts Disassembled parts are easy to confuse. Arrange the parts according to the order the parts were disassembled and clean the parts in order prior to assembly. Storage of Removed Parts Afterallthepartsincludingsubassemblypartshavebeen cleaned, store the parts in a clean area. Put a clean cloth or plastic sheet over the parts to protect from any foreign materials that may collect before re-assembly. Inspection Reuseof
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1-4 GENERAL INFORMATION Before Servicing Tightening Sequence Bolts, nuts, orscrewsmust betightened accordingtothe specifiedsequencetopreventcasewarpageordeformation which can lead to malfunction. If the specified tightening sequence is not indicated, tighten the fasteners alternating diagonally. Tightening Torque Incorrect torque applied to a bolt, nut, or screw may lead to serious damage. Tighten fasteners to the specified torque using a good quality torque wrench. Often, the tightening sequenc
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GENERAL INFORMATION 1-5 Before Servicing Press For items such as bearings or oil seals that must be pressed into place, apply small amount of oil to the con- tact area. Be sure to maintain proper alignment and use smooth movements when installing. Ball Bearing and Needle Bearing Do not remove pressed ball or needle unless removal is absolutely necessary. Replace with new ones whenever removed. Press bearings with the manufacturer and size marks facing out. Press the bearing into place by putting
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1-6 GENERAL INFORMATION Before Servicing Direction of Engine Rotation When rotating the crankshaft by hand, the free play amount of rotating direction will affect the adjustment. Ro- tate the crankshaft to positive direction (clockwise viewed from output side). Electrical Wires Atwo-colorwireisidentifiedfirstbytheprimarycolorand thenthestripecolor. Unlessinstructedotherwise,electrical wires must be connected to those of the same color.
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GENERAL INFORMATION 1-7 Model Identification ZR750–J1 Left Side View: ZR750–J1 Right Side View:
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1-8 GENERAL INFORMATION General Specifications Items ZR750–J1 Dimensions: Overall length 2 080 mm (81.9 in.) Overall width 780 mm (30.7 in.) Overall height 1 055 mm (41.5 in.) Wheelbase 1 425 mm (56.1 in.) Road clearance 165 mm (6.5 in.) Seat height 815 mm (32.1 in.) Dry mass 195 kg (430.0 lb) Curb mass: Front 111 kg (244.8 lb) Rear 107 kg (235.9 lb) Fuel tank capacity 18 L (5.0 US gal.) Performance: Minimum turning radius 2.9 m (9.5 ft) Engine: Type 4-stroke, DOHC, 4-cylinder Cooling system Liq
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GENERAL INFORMATION 1-9 General Specifications Items ZR750–J1 Viscosity SAE 10W-40 Capacity 3.8 L (4.0 US qt) Drive Train: Primary reduction system: Type Gear Reduction ratio 1.714 (84/49) Clutch type Wet multi disc Transmission: Type 6-speed, constant mesh, return shift Gear ratios: 1st 2.571 (36/14) 2nd 1.941 (33/17) 3rd 1.555 (28/18) 4th 1.333 (28/21) 5th 1.200 (24/20) 6th 1.095 (23/21) Final drive system: Type Chain drive Reduction ratio 2.867 (43/15) Overall drive ratio 5.382 @Top gear Fram
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1-10 GENERAL INFORMATION Technical Information – Air Inlet System Subthrottle Control System The ZR750–J1 employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large bore. Therefore two throttle valves are placed in each inlet tract, the main throttle valvelocatedclosesttothecylinderandasubthrottlevalveplacedfurtheruptheinlettract. Themain throttle valve is opera
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GENERAL INFORMATION 1-11 Technical Information – Air Inlet System Operation The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a steppingmotorbuiltinit,ECU,andsubthrottlesensor. Thesubthrottlevalveisbuiltintheeachthrottle body. ThesubthrottlecontrolsystemoperatesonthesignalsuppliedfromtheECU.Theopen/closeoper- ation of the subthrottle valve is performed by the subthrottle actuator which is controlled by the ECU to change the current direction into t
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1-12 GENERAL INFORMATION Technical Information – New Ignition Interlock Sidestand Outline The New Ignition Interlock Sidestand System applied to ZR750–J1 models that cannot function if gearsareengagedand/orthesidestandisnot liftedupwardeventhoughclutchleverpulledin,which differs from the traditional one. Refer to the tables below as to the engine starts and/or the driving at each condition. New Ignition Interlock Sidestand System Side Stand Gear Position Clutch Lever Engine Start Engine Run A Up
