Kawasaki 2004 ZR750–J1 User manual

Category
Motorcycles
Type
User manual

This manual is also suitable for

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 chapter num-
ber with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the spe-
cific topic required.
Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System (DFI) 3 j
Cooling System 4 j
Engine Top End 5 j
Clutch 6 j
Engine Lu brication System 7 j
Engine Removal/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
Z750
All rights reserved. No parts of this publication m ay 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 m ake it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously. See your Motorcycle dealer for the latest
information on product improvements incorporated after this publication.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2003 Kawasaki Heavy Industries, Ltd. First Edition (1) : Sep. 16, 2003 (M)
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 watt(s)
h hour(s) ohm(s)
L liter(s)
Read OWNER’S MANUAL before operating.
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic in-
formation to make it useful to the owner who de-
sires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop proce-
dures must be understood in order to carry out
maintenance and repair satisfactorily. When-
ever the owner has insufficient experience or
doubts his ability to do the work, all adjust-
ments, maintenance, and repair should be car-
ried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thor-
oughly familiarize yourself with the procedures
before starting w ork, and then do the work care-
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may ad-
versely affect safe operation.
For the duration of the warranty period,
we recommend that all repairs and scheduled
maintenance be performed in accordance with
this service manual. Any owner maintenance or
repair procedure not performed in accordance
with this manual may void the warranty.
To get the longest life out of your vehicle:
Follow the Periodic Maintenance Chart in t he
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki Mo-
torcycle parts. Special tools, gauges, and
testers that are necessary when servicing
Kawasaki motorcycles are introduced by the
Special Tool Catalog or Manual. Genuine
parts provided as spare parts are listed in the
Parts Catalog.
Follow the procedures in this manual care-
fully. Don’t take shortcuts.
Remember to keep complete records of main-
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In preparing this manual, we divided the prod-
uct into its major systems. These systems be-
came the manual’s chapters. All information
for a particular system from adjustment through
disassembly and inspection is located i n a sin-
gle chapter.
The Quick Reference Guide shows you all
of the product’s system and assists in locating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
The Periodic Maintenance Chart is located in
the Periodic Maintenance chapter. The chart
gives a time schedule for required maintenance
operations.
If you want spark plug information, for exam-
ple, go to the Periodic Maintenance Chart first.
The chart tells you how frequently to clean and
gap the plug. Next, use the Quick Reference
Guide to locate the P eriodic Maintenance chap-
ter. Then, use the Table of Contents on the first
page of the chapter to find the Spark P lug sec-
tion.
Whenever you see these WARNING and
CAUTION symbols, heed their i nstructions!
Always follow safe operating and m aintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures w hich, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures w hich, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of informa-
tion.
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
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require spec-
ified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
1
General Information
Table of Cont ent s
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-7
General Specifications............................................................................................................ 1-8
Technical Information Air Inlet System ................................................................................ 1-10
Technical Information New Ignition Interlock Sidestand ...................................................... 1-12
Technical Information Tail/Brake Lights Employing LED ..................................................... 1-13
Technical Information KAWASAK I LOW EXHAUST EM ISSION SYSTEM ......................... 1-15
Unit Conversion Table ............................................................................................................ 1-16
1-2 GENERAL INFORMATION
Before Servicing
Before starting to perform an inspection service or carry out a disassembly and reassembly opera-
tion on a motorcycle, read the precautions given below. To facilitate actual operations, notes, illustra-
tions, photographs, cautions, and detailed descriptions have been included in each chapter wherever
necessary. This section explains the i tems that require particular attention during the removal and
reinstallation or disassembly and reassembly of general parts.
Especially note the following:
Battery Ground
Before completing any service on the motorcycle, discon-
nect the battery wires from the battery to prevent the engine
from accidentally turning over. Disconnect the ground w ire
(–) first and then the positive (+). When completed with the
service, first connect the positive (+) wire to the positive (+)
terminal of the battery then the negative (–) wire to the neg-
ative terminal.
Edges of Parts
Lift large or heavy parts wearing gloves to prevent injury
from possible sharp edges on the parts.
Solvent
Use a high flush point solvent when cleaning parts. High
flush point solvent should be used according to directions
of the solvent manufacturer.
Cleaning vehicle before disassembly
Clean the vehicle thoroughly before disassembly. Dirt or
other foreign materials entering into sealed areas during ve-
hicle disassembly can cause excessive wear and decrease
performance of the vehicle.
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
After all the parts including subassembly parts have been
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
Reuse of worn or damaged parts may lead to serious ac-
cident. Visually inspect removed parts for corrosion, discol-
oration, or other damage. Refer to the appropriate sections
of this manual for service limits on individual parts. Replace
the parts if any damage has been found or if the part is be-
yond its service limit.
Replacement Parts
Replacement parts must be KAWASAKI genuine or
recommended by KAWASAKI. Gaskets, O-rings, oil seals,
grease seals, circlips or cotter pins must be replaced with
new ones whenever disassembled.
Assembly Order
In most cases assembly order is the reverse of disassem-
bly, however, if assembly order is provided in this Service
Manual, follow the procedures given.
1-4 GENERAL INFORMATION
Before Servicing
Tightening Sequence
Bolts, nuts, or screws must be t ightened according to the
specified sequence to prevent case warpage or deformation
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 t o the specified
torque using a good quality torque wrench. Often, the
tightening sequence is followed twice-initial tightening and
final tightening with torque wrench.
Force
Usecommonsenseduringdisassemblyandassembly,
excessive force can cause expensive or hard to repair dam-
age. When necessary, remove screws that have a non
-permanent locking agent applied using an impact driver.
Use a plastic-faced mallet whenever tapping is necessary.
Gasket, O-ring
Hardening, shrinkage, or damage of both gaskets
and O-rings after disassembly can reduce sealing per-
formance. Remove old gaskets and clean the sealing
surfaces thoroughly so that no gasket m aterial or other
material remains. Install new gaskets and replace used
O-rings when re-assembling
Liquid Gasket, Locking Agent
For applications that require Liquid Gasket or a Locking
agent, clean the surfaces so that no oil residue remains be-
fore applying liquid gasket or locking agent. Do not apply
them excessively. Excessive application can clog oil pas-
sages and cause serious damage.
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
pressure on the correct bearing race as shown.
Pressing the incorrect race can cause pressure between
the inner and outer race and result in bearing damage.
Oil Seal, Grease Seal
Do not remove pressed oil or grease seals unless removal
is necessary. Replace with new ones whenever removed.
Press new oil seals with m anufacture and size marks facing
out. Make sure the seal is aligned properly when installing.
Circlips, Cotter Pins
Replace circlips or cotter pins that were removed with new
ones. Install the circlip with its sharp edge facing outward
and its chamfered side facing inward to prevent the clip from
being pushed out of its groove when loaded. Take care
not to open the clip excessively when installing to prevent
deformation.
Lubrication
It is important to lubricate rotating or sliding parts during
assembly to minimize wear during initial operation. Lubri-
cation points are called out throughout this manual, apply
the specific oil or grease as specified.
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
A two-color wire is identified first by the primary color and
then the stripe color. Unless instructed otherwise, electrical
wires must be connected to those of the same color.
GENERAL INFORMATION 1-7
Model Identification
ZR750–J1 Left Side View:
ZR750–J1 Right Side View:
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 Liquid-cooled
Bore and stroke 68.4 × 50.9 mm (2.7 × 2.0 in.)
Displacement 748 mL (45.64 cu in.)
Compression ratio 11.3
Maximum horsepower 79 kW (107 PS) @10 500 r/min ( rpm),
(MY, AU) 80 kW (109 PS) @11 000 r/min (rpm)
(HR) 78.2 kW (106 PS) @11 000 r/min (rpm)
Maximum t orque 75 N·m ( 7.6 kgf·m, 55 ft·lb) @8 200 r/min (rpm),
(HR) 73 N·m (7.4 kgf·m, 54 ft·lb) @ 8 200 r/min (rpm)
Carburetion system FI (Fuel Injection) KEIHIN TTK34 × 4
Starting system Electric starter
Ignition system Battery and coil (transistorized)
Ti ming advance Electronically advanced (digital igniter)
Ignition timi
ng
From 10° BTDC @1 100 r/min ( rpm) to 37° BTDC
@5 800 r/min (rpm)
Spark plug NGK CR9EK or ND U27ETR
Cylinder numbering m ethod Left to right, 1-2-3-4
Firing order 1-2-4-3
Valve timing:
Inlet Open 38° BTDC
Close 66° ABDC
Duration 284°
Exhaust Open 57° BBDC
Close 31° ATDC
Duration 268°
Lubrication system Forced lubrication (wet sump)
Engine oil:
Type API SE, SF or SG
API SH or SJ wi th JASO MA
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, r eturn 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
Frame:
Type Tubular, diamond
Caster (rake angle) 24.5°
Trail 104 mm (4.1 in.)
Front tire: Type Tubeless
Size 120/70 ZR17 M/C (58W)
Rear tire: Type Tubeless
Size 180/55 ZR17 M/C (73W)
Front suspension: Type Telescopic fork (upside-down)
Wheel travel 120 mm (4.7 in.)
Rear suspension: Type Swingarm (uni-trak)
Wheel travel 126 mm (5.0 in.)
Brake Type: Front Dual discs
Rear
Single disc
Electrical Equipment:
Battery 12 V 8 Ah
Headlight: Type Semi-sealed beam
Bulb 12 V 55 W × 2/55 W (Hi/Lo)
Tail/brake light 12 V 0.5/3.8 W (LED), (CA) 12 V 0.5/5W (LED)
Alternator: Type Three-phase AC
Rated output 24 A/14 V @5 000 r/min (rpm)
Specifications are subject to change without notice, and may not apply t o every country.
(AU): Australia Model
(CA): Canada Model
(MY): Malaysia M odel
(HR): with Honeycomb Catalytic Converter Model (Restricted model)
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
valve located closest to the cylinder and a subthrottle valve placed further up the inlet tract. The main
throttle valve is operated by the rider when the throttle grip is turned clockwise or counterclockwise,
while the subthrottle valve is operated by a stepping motor controlled by t he ECU. The subthrottle
valve automatically adjusts air inlet to m ore precisely match engine demand, so that when the main
throttle is opened quickly there is no hesitation or jerky response.
The subthrottle valves allow the fuel injection system to provide smooth throttle response, similar to
that of a constant velocity carburetor, no matter how quickly the throttle is opened.
A. Main Throttle Valve
B. Subthrottle Valve
C. Throttle Valve
D. Vacuum Piston
E. Inlet Air
GENERAL INFORMATION 1-11
Technical Information A ir Inlet System
Operation
The subthrottle control system consists of the subthrottle valve, subthrottle valve actuator with a
stepping motor built in it, ECU, and subthrottle sensor. The subthrottle valve is built in the each throttle
body.
The subthrottle control system operates on the signal supplied from the ECU. The open/close oper-
ation of the subthrottle valve is performed by the subthrottle actuator which is controlled by the ECU
to change the current direction into the motor of the subthrottle valve actuator.
The s ubthrottle sensor detects the subthrottle valve actuator movement by m easuring voltage and
the EC U determines the subthrottle valve angle based on the operation m ap.
When turning the ignition switch O N, every time the ECU automatically drives the subthrottle valve
from fully closed position to fully opened position. The ECU memorizes these positions and turns
back the subthrottle valve to the original point to confirm the subthrottle valve idling voltage.
A. Subthrottle Valves
B. Subthrottle Valve Actuator
C. Subthrottle Sensor
D. Main Throttle Sensor
E. ECU (Electric Control Unit)
F. Air Cleaner Side
G. Crankshaft Sensor
H. Speed Sensor
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
gears are engaged and/or the sidestand is not lifted upward even though clutch lever pulled in, 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 Neutral Released Starts Continue running
B Up Neutral Pulled in Starts Continue running
C Up In Gear Released Doesn’t start Continue running
D Up In Gear Pulled in Starts Continue running
E Down Neutral Released Starts Continue running
F Down Neutral Pulled in Starts Continue running
G Down In Gear Released Doesn’t start Stops
H Down In Gear Pulled in Doesn’t start Stops
Current Igni tion Interlock Sidestand System
Side Stand Gear Position Clutch Lever Engine Start Engine Run
A Up Neutral R eleased Starts Continue running
B Up Neutral Pulled in Starts Continue running
C Up In Gear Released Doesn’t start Continue running
D Up In Gear Pulled in Starts Continue running
E Down Neutral Released
Starts Continue running
F Do
wn
Ne
utral
Pu
lled in
Starts Continue running
G Down In Gear Released Doesn’t start Stops
H Down In Gear Pulled in Start Continue running
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Kawasaki 2004 ZR750–J1 User manual

Category
Motorcycles
Type
User manual
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