Kawasaki Z750s Service Manual

Motorcycle

Thisquickreferenceguidewillassist youinlocatingadesiredtopicorprocedure.

•Bendthepagesbacktomatchthe blacktabofthedesiredchapternumberwiththeblacktabontheedgeat eachtableofcontentspage.

•Refertothesectionaltableofcontents fortheexactpagestolocatethespecifictopicrequired.

Motorcycle ServiceManual

Allrightsreserved.Nopartsofthispublicationmaybereproduced,storedinaretrievalsystem,or transmittedinanyformorbyanymeans,electronicmechanicalphotocopying,recordingorotherwise, withoutthepriorwrittenpermissionofQualityDivision/ConsumerProducts&MachineryCompany/Kawasaki HeavyIndustries,Ltd.,Japan.

Noliabilitycanbeacceptedforanyinaccuraciesoromissionsinthispublication,althougheverypossible carehasbeentakentomakeitascompleteandaccurateaspossible.

Therightisreservedtomakechangesatanytimewithoutpriornoticeandwithoutincurringanobligation tomakesuchchangestoproductsmanufacturedpreviously.SeeyourMotorcycledealerforthelatest informationonproductimprovementsincorporatedafterthispublication.

Allinformationcontainedinthispublicationisbasedonthelatestproductinformationavailableatthetime ofpublication.Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmay notdepictactualmodelcomponentparts.

LISTOFABBREVIATIONS

A ampere(s) lb pound(s)

ABDC afterbottomdeadcenter m meter(s)

AC alternatingcurrent min minute(s)

ATDC aftertopdeadcenter N newton(s)

BBDC beforebottomdeadcenter Pa pascal(s)

BDC bottomdeadcenter PS horsepower

BTDC beforetopdeadcenter psi pound(s)persquareinch °C degree(s)Celsius r revolution DC directcurrent rpm revolution(s)perminute F farad(s) TDC topdeadcenter °F degree(s)Fahrenheit TIR totalindicatorreading ft foot,feet V volt(s) g gram(s) W watt(s) h hour(s) Ω ohm(s) L liter(s)

Toprotecttheenvironmentinwhichwealllive,Kawasakihasincorporatedcrankcaseemission(1)andexhaustemission(2)controlsystemsincompliancewithapplicableregulationsof theUnitedStatesEnvironmentalProtectionAgencyandCaliforniaAirResourcesBoard.Additionally,Kawasakihasincorporatedanevaporativeemissioncontrolsystem(3)incompliance withapplicableregulationsoftheCaliforniaAirResourcesBoardonvehiclessoldinCalifornia only.

1.CrankcaseEmissionControlSystem

Thissystemeliminatesthereleaseofcrankcasevaporsintotheatmosphere.Instead,thevapors areroutedthroughanoilseparatortotheintakesideoftheengine.Whiletheengineisoperating, thevaporsaredrawnintocombustionchamber,wheretheyareburnedalongwiththefuelandair suppliedbythefuelinjectionsystem.

2.ExhaustEmissionControlSystem

Thissystemreducestheamountofpollutantsdischargedintotheatmospherebytheexhaust ofthismotorcycle.Thefuel,ignition,andexhaustsystemsofthismotorcyclehavebeencarefully designedandconstructedtoensureanefficientenginewithlowexhaustpollutantlevels.

TheexhaustsystemofthismodelmotorcyclemanufacturedprimarilyforsaleinCaliforniaincludes acatalyticconvertersystem.

3.EvaporativeEmissionControlSystem

Vaporscausedbyfuelevaporationinthefuelsystemarenotventedintotheatmosphere.Instead,fuelvaporsareroutedintotherunningenginetobeburned,orstoredinacanisterwhen theengineisstopped.Liquidfueliscaughtbyavaporseparatorandreturnedtothefueltank.

TheCleanAirAct,whichistheFederallawcoveringmotorvehiclepollution,containswhatis commonlyreferredtoastheAct’s"tamperingprovisions."

"Sec.203(a)Thefollowingactsandthecausingthereofareprohibited...

(3)(A)foranypersontoremoveorrenderinoperativeanydeviceorelementofdesigninstalled onorinamotorvehicleormotorvehicleengineincompliancewithregulationsunderthis titlepriortoitssaleanddeliverytotheultimatepurchaser,orforanymanufacturerordealer knowinglytoremoveorrenderinoperativeany suchdeviceorelementofdesignaftersuch saleanddeliverytotheultimatepurchaser.

(3)(B)foranypersonengagedinthebusinessofrepairing,servicing,selling,leasing,ortrading motorvehiclesormotorvehicleengines,orwhooperatesafleetofmotorvehiclesknowinglytoremoveorrenderinoperativeanydeviceorelementofdesigninstalledonorina motorvehicleormotorvehicleengineincompliancewithregulationsunderthistitlefollowingitssaleanddeliverytotheultimatepurchaser..."

NOTE

Federallawprohibitsthefollowingactsorthecausingthereof:(1)Theremovalorrendering inoperativebyanypersonotherthanforpurposesofmaintenance,repair,orreplacement,ofany deviceorelementofdesignincorporatedintoanynewvehicleforthepurposeofnoisecontrol priortoitssaleordeliverytotheultimatepurchaserorwhileitisinuse,or(2)theuseofthe vehicleaftersuchdeviceorelementofdesignhasbeenremovedorrenderedinoperativeby anyperson.

Amongthoseactspresumedtoconstitutetamperingaretheactslistedbelow:

• Replacementoftheoriginalexhaustsystemormufflerwithacomponentnotincompliance withFederalregulations.

• Removalofthemuffler(s)oranyinternalportionofthemuffler(s).

• Removaloftheairboxorairboxcover.

• Modificationstothemuffler(s)orairinletsystembycutting,drilling,orothermeansifsuch modificationsresultinincreasednoiselevels.

Foreword

Thismanualisdesignedprimarilyforuseby trainedmechanicsinaproperlyequippedshop. However,itcontainsenoughdetailandbasicinformationtomakeitusefultotheownerwhodesirestoperformhisownbasicmaintenanceand repairwork.Abasicknowledgeofmechanics, theproperuseoftools,andworkshopproceduresmustbeunderstoodinordertocarryout maintenanceandrepairsatisfactorily.Whenevertheownerhasinsufficientexperienceor doubtshisabilitytodothework,alladjustments,maintenance,andrepairshouldbecarriedoutonlybyqualifiedmechanics.

Inordertoperformtheworkefficientlyand toavoidcostlymistakes,readthetext,thoroughlyfamiliarizeyourselfwiththeprocedures beforestartingwork,andthendotheworkcarefullyinacleanarea.Wheneverspecialtoolsor equipmentarespecified,donotusemakeshift toolsorequipment.Precisionmeasurements canonlybemadeiftheproperinstrumentsare used,andtheuseofsubstitutetoolsmayadverselyaffectsafeoperation.

Forthedurationofthewarrantyperiod, werecommendthatallrepairsandscheduled maintenancebeperformedinaccordancewith thisservicemanual.Anyownermaintenanceor repairprocedurenotperformedinaccordance withthismanualmayvoidthewarranty.

Togetthelongestlifeoutofyourvehicle:

• FollowthePeriodicMaintenanceChartinthe ServiceManual.

• Bealertforproblemsandnon-scheduled maintenance.

• UsepropertoolsandgenuineKawasakiMotorcycleparts.Specialtools,gauges,and testersthatarenecessarywhenservicing Kawasakimotorcyclesareintroducedbythe SpecialToolCatalogorManual.Genuine partsprovidedassparepartsarelistedinthe PartsCatalog.

• Followtheproceduresinthismanualcarefully.Don’ttakeshortcuts.

• Remembertokeepcompleterecordsofmaintenanceandrepairwithdatesandanynew partsinstalled.

HowtoUseThisManual

Inpreparingthismanual,wedividedtheproductintoitsmajorsystems.Thesesystemsbecamethemanual’schapters.Allinformation foraparticularsystemfromadjustmentthrough disassemblyandinspectionislocatedinasinglechapter.

TheQuickReferenceGuideshowsyouall oftheproduct’ssystemandassistsinlocating theirchapters.Eachchapterinturnhasitsown comprehensiveTableofContents.

ThePeriodicMaintenanceChartislocatedin thePeriodicMaintenancechapter.Thechart givesatimescheduleforrequiredmaintenance operations.

Ifyouwantsparkpluginformation,forexample,gotothePeriodicMaintenanceChartfirst. Thecharttellsyouhowfrequentlytocleanand gaptheplug.Next,usetheQuickReference GuidetolocatethePeriodicMaintenancechapter.Then,usetheTableofContentsonthefirst pageofthechaptertofindtheSparkPlugsection.

WheneveryouseetheseWARNINGand CAUTIONsymbols,heedtheirinstructions! Alwaysfollowsafeoperatingandmaintenance practices.

WARNING

Thiswarningsymbolidentifiesspecial instructionsorprocedureswhich,ifnot correctlyfollowed,couldresultinpersonalinjury,orlossoflife.

CAUTION

Thiscautionsymbolidentifiesspecial instructionsorprocedureswhich,ifnot strictlyobserved,couldresultindamagetoordestructionofequipment.

Thismanualcontainsfourmoresymbols(in additiontoWARNINGandCAUTION)whichwill helpyoudistinguishdifferenttypesofinformation.

NOTE

○Thisnotesymbolindicatespointsofparticularinterestformoreefficientandconvenientoperation.

• Indicatesaproceduralsteporworktobe done.

○Indicatesaproceduralsub-steporhowtodo theworkoftheproceduralstepitfollows.It alsoprecedesthetextofaNOTE. Indicatesaconditionalsteporwhatactionto takebasedontheresultsofthetestorinspectionintheproceduralsteporsub-stepitfollows.

Inmostchaptersanexplodedviewillustration ofthesystemcomponentsfollowstheTableof Contents.Intheseillustrationsyouwillfindthe instructionsindicatingwhichpartsrequirespecifiedtighteningtorque,oil,greaseoralocking agentduringassembly.

1-2GENERALINFORMATION

BeforeServicing

Beforestartingtoperformaninspectionserviceorcarryoutadisassemblyandreassemblyoperationonamotorcycle,readtheprecautionsgivenbelow.Tofacilitateactualoperations,notes,illustrations,photographs,cautions,anddetaileddescriptionshavebeenincludedineachchapterwherever necessary.Thissectionexplainstheitemsthatrequireparticularattentionduringtheremovaland reinstallationordisassemblyandreassemblyofgeneralparts.

Especiallynotethefollowing:

BatteryGround

Beforecompletinganyserviceonthemotorcycle,disconnectthebatterywiresfromthebatterytopreventtheengine fromaccidentallyturningover.Disconnectthegroundwire (–)firstandthenthepositive(+).Whencompletedwiththe service,firstconnectthepositive(+)wiretothepositive(+) terminalofthebatterythenthenegative(–)wiretothenegativeterminal.

EdgesofParts

Liftlargeorheavypartswearingglovestopreventinjury frompossiblesharpedgesontheparts.

Solvent

Useahigh-flushpointsolventwhencleaningparts.High -flushpointsolventshouldbeusedaccordingtodirections ofthesolventmanufacturer.

Cleaningvehiclebeforedisassembly

Cleanthevehiclethoroughlybeforedisassembly.Dirtor otherforeignmaterialsenteringintosealedareasduringvehicledisassemblycancauseexcessivewearanddecrease performanceofthevehicle.

BeforeServicing

ArrangementandCleaningofRemovedParts

Disassembledpartsareeasytoconfuse.Arrangethe partsaccordingtotheorderthepartsweredisassembled andcleanthepartsinorderpriortoassembly.

StorageofRemovedParts

Afterallthepartsincludingsubassemblypartshavebeen cleaned,storethepartsinacleanarea.Putacleancloth orplasticsheetoverthepartstoprotectfromanyforeign materialsthatmaycollectbeforere-assembly.

Inspection

Reuseofwornordamagedpartsmayleadtoseriousaccident.Visuallyinspectremovedpartsforcorrosion,discoloration,orotherdamage.Refertotheappropriatesections ofthismanualforservicelimitsonindividualparts.Replace thepartsifanydamagehasbeenfoundorifthepartisbeyonditsservicelimit. ReplacementParts

ReplacementpartsmustbeKAWASAKIgenuineor recommendedbyKAWASAKI.Gaskets,O-rings,oilseals, greaseseals,circlipsorcotterpinsmustbereplacedwith newoneswheneverdisassembled.

AssemblyOrder

Inmostcasesassemblyorderisthereverseofdisassembly,however,ifassemblyorderisprovidedinthisService Manual,followtheproceduresgiven.

BeforeServicing

TighteningSequence

Generally,wheninstallingapartwithseveralbolts,nuts, orscrews,startthemallintheirholesandtightenthemto asnugfit.Thentightenthemaccordingtothespecifiedsequencetopreventcasewarpageordeformationwhichcan leadtomalfunction.Converselywhenlooseningthebolts, nuts,orscrews,firstloosenallofthembyaboutaquarterturnandthenremovethem.Ifthespecifiedtightening sequenceisnotindicated,tightenthefastenersalternating diagonally.

TighteningTorque

Incorrecttorqueappliedtoabolt,nut,orscrewmay leadtoseriousdamage.Tightenfastenerstothespecified torqueusingagoodqualitytorquewrench.Often,the tighteningsequenceisfollowedtwice-initialtighteningand finaltighteningwithtorquewrench.

Force

Usecommonsenseduringdisassemblyandassembly, excessiveforcecancauseexpensiveorhardtorepairdamage.Whennecessary,removescrewsthathaveanon -permanentlockingagentappliedusinganimpactdriver. Useaplastic-facedmalletwhenevertappingisnecessary.

Gasket,O-ring

Hardening,shrinkage,ordamageofbothgaskets andO-ringsafterdisassemblycanreducesealingperformance.Removeoldgasketsandcleanthesealing surfacesthoroughlysothatnogasketmaterialorother materialremains.Installnewgasketsandreplaceused O-ringswhenre-assembling

LiquidGasket,Non-permanentLockingAgent

ForapplicationsthatrequireLiquidGasketora Non-permanentLockingAgent,cleanthesurfacesso thatnooilresidueremainsbeforeapplyingliquidgasketor non-permanentlockingagent.Donotapplythemexcessively.Excessiveapplicationcanclogoilpassagesand causeseriousdamage.

BeforeServicing

Press

Foritemssuchasbearingsoroilsealsthatmustbe pressedintoplace,applysmallamountofoiltothecontactarea.Besuretomaintainproperalignmentanduse smoothmovementswheninstalling.

BallBearingandNeedleBearing

Donotremovepressedballorneedleunlessremovalis absolutelynecessary.Replacewithnewoneswhenever removed.Pressbearingswiththemanufacturerandsize marksfacingout.Pressthebearingintoplacebyputting pressureonthecorrectbearingraceasshown.

Pressingtheincorrectracecancausepressurebetween theinnerandouterraceandresultinbearingdamage.

OilSeal,GreaseSeal

Donotremovepressedoilorgreasesealsunlessremoval isnecessary.Replacewithnewoneswheneverremoved. Pressnewoilsealswithmanufactureandsizemarksfacing out.Makesurethesealisalignedproperlywheninstalling.

Applyspecifiedgreasetothelipofsealbeforeinstalling theseal.

Circlips,CotterPins

Replacecirclipsorcotterpinsthatwereremovedwithnew ones.Takecarenottoopentheclipexcessivelywheninstallingtopreventdeformation.

1-6GENERALINFORMATION

BeforeServicing

Lubrication

Itisimportanttolubricaterotatingorslidingpartsduring assemblytominimizewearduringinitialoperation.Lubricationpointsarecalledoutthroughoutthismanual,apply thespecificoilorgreaseasspecified.

DirectionofEngineRotation

Whenrotatingthecrankshaftbyhand,thefreeplay amountofrotatingdirectionwillaffecttheadjustment.Rotatethecrankshafttopositivedirection(clockwiseviewed fromoutputside).

ElectricalWires

Atwo-colorwireisidentifiedfirstbytheprimarycolorand thenthestripecolor.Unlessinstructedotherwise,electrical wiresmustbeconnectedtothoseofthesamecolor.

GeneralSpecifications

Items ZR750-K1

Dimensions

OverallLength 2080mm(81.9in.)

OverallWidth 780mm(30.7in.)

OverallHeight 1180mm(46.5in.)

Wheelbase 1425mm(56.1in.)

RoadClearance 165mm(6.5in.)

SeatHeight 805mm(31.7in.)

DryMass 199kg(438.8lb)

CurbMass: Front 113kg(249.2lb) Rear 109kg(240.3lb)

FuelTankCapacity 18L(5.0USgal.)

Performance

MinimumTurningRadius 2.9m(9.5ft)

Engine

Type

4-stroke,DOHC,4-cylinder

CoolingSystem Liquid-cooled

BoreandStroke 68.4×50.9mm(2.7×2.0in.)

Displacement 748mL(45.64cuin.)

CompressionRatio 11.3:1

MaximumHorsepower 81kW(110PS)@11000r/min(rpm), (MY)80kW(109PS)@11000r/min(rpm) (HR)78.2kW(106PS)@11000r/min(rpm) (US,CA)–––

MaximumTorque 75N·m(7.6kgf·m,55ft·lb)@8200r/min(rpm), (HR)73N·m(7.4kgf·m,54ft·lb)@8200r/min(rpm) (US,CA)–––

1-10GENERALINFORMATION

GeneralSpecifications

Items ZR750-K1

Duration 268°

LubricationSystem Forcedlubrication(wetsump)

EngineOil: Type APISE,SForSG APISHorSJwithJASOMA Viscosity SAE10W-40 Capacity 3.8L(4.0USqt)

DriveTrain

PrimaryReductionSystem: Type Gear ReductionRatio 1.714(84/49)

ClutchType Wetmultidisc Transmission: Type 6-speed,constantmesh,returnshift

GearRatios: 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)

FinalDriveSystem: Type Chaindrive ReductionRatio 2.867(43/15) OverallDriveRatio 5.382@Topgear

Frame

Type Tubular,diamond Caster(RakeAngle) 25° Trail 107mm(4.2in.)

FrontTire: Type Tubeless Size 120/70ZR17M/C(58W)

RearTire: Type Tubeless Size 180/55ZR17M/C(73W)

FrontSuspension: Type Telescopicfork WheelTravel 120mm(4.7in.)

RearSuspension: Type Swingarm(uni-trak) WheelTravel 126mm(5.0in.)

BrakeType: Front Dualdiscs Rear Singledisc