![Kawasaki NINJA ZX-7RR (1997-2003) [103/364] Engine top end](/img/pdf.png)
Kawasaki NINJA ZX-7RR (1997-2003) [103/364] Engine top end
![Kawasaki NINJA ZX-7RR (1997-2003) [103/364] Engine top end](/views2/1121191/page103/bg67.png)
Содержание
- Read owner s manual before operating 2
- Quick reference guide 3
- Emission control information 5
- Tampering with noise control system prohibited 6
- Caution 7
- Foreword 7
- How to use this manual 7
- Warning 7
- This note symbol indicates points of partic 8
- Ular interest for more efficient and convenient operation 8
- General information 9
- General information 1 1 9
- Table of contents 9
- 2 general information 10
- Before servicing 10
- General information 1 3 11
- 6 general information 14
- General information 1 7 15
- 8 general information 16
- General specifications 16
- General information 1 9 17
- 10 general information 18
- General information 1 11 19
- 12 general information ____________________________________________________ 20
- Periodic maintenance chart 20
- General information 1 13 21
- Technical information maintenance free battery 21
- 14 general information 22
- General information 1 15 23
- 16 general information 24
- Accelerator pumps 25
- General information 1 17 25
- Technical information flat cr slide carburetor 25
- Throttle mechanism 25
- 18 general information 26
- A fuel tank b fuel pump c fuel gallery d enricher solenoid valve e enricher jet 26
- Between 1 500 rpm and 5 000 rpm the fuel enricher solenoid valve opens and pressured fuel is available to the accelerator pump chamber 26
- Chambers 26
- F accelerator pump 26
- From flooding the float bowl instead fuel passes through the accelerator pump outlet check valve and out the discharge nozzle 26
- Fuel enricher 26
- G discharge nozzles h throttle switch i ic igniter 26
- Improve throttle response at lower engine speeds and prevent misfiring when the throttle is quickly opened 26
- Is more than 3 8 open the ic igniter senses the throttle switch signal and engine speed and actuates the fuel enricher solenoid valve accord ing to the conditions above 26
- The accelerator pump inlet check valve closes preventing enricher fuel 26
- The fuel enricher provides a richer mixture to the engine in order to 26
- The fuel flows as shown 26
- The throttle switch sends a signal to the ic igniter when the throttle 26
- When the throttle is more than 3 8 open and the engine is turning 26
- General information 1 19 27
- Technical information side camshaft chain 27
- 20 general information___________________ 28
- Technical information engine lubrication system 28
- Ben if its 29
- Technical information connecting rod big end nut tightening________ 29
- _______ general information 1 21 29
- 22 general information 30
- General information 1 23 31
- 24 general information 32
- Technical information alternator unit 32
- Technical information swingarm 32
- General information 1 25 33
- Torque and locking agent 33
- 26 general information 34
- General information 1 27 35
- 28 general information 36
- General information 1 29 37
- 30 general information 38
- Special tools and sealant 38
- General information 1 31 39
- 32 general information 40
- General information 1 33 41
- 34 general information 42
- 36 general information 44
- Cable wire and hose routing 44
- General information 1 37 45
- 38 general information 46
- General information 1 39 47
- 40 general information 48
- General information 1 41 49
- 42 general information 50
- 44 general information 52
- 46 general information 54
- General information 1 47 55
- 48 general information 56
- Fuel system 57
- Fuel system 2 1 57
- Table of contents 57
- Fuel system 59
- Fuel system 2 3 61
- 4 fuel system 62
- 6 fuel system 64
- Specifications 64
- Fuel system 2 7 65
- 8 fuel system 66
- Cable installation 66
- Free play adjustment 66
- Free play inspection 66
- Throttle grip and cables 66
- Cable lubrication 67
- Fuel system 2 9 67
- 10 fuel system 68
- Cable installation 68
- Cable lubrication 68
- Choke cable 68
- Free play adjustment 68
- Free play inspection 68
- Be improperly adjusted or incorrectly routed or damaged be sure to correct any of these conditions before riding see cable routing section in general information chapter 69
- Carburetors ___________ ___________________ ____ 69
- Check idle speed 69
- Fuel system 2 11 69
- Idle speed adjustment 69
- Idle speed inspection 69
- If handlebar movement changes the idle speed the throttle cables may 69
- If the idle speed is out of the specified range adjust it 69
- Remove the fuel tank see fuel tank removal connect a fuel tank to the carburetors with a suitable hose screw in the idle adjusting screw about three threads this is the point 69
- Speed is within the specified range readjust if necessary 69
- Start the engine and warm it up thoroughly 69
- Start the engine and warm it up thoroughly turn the adjusting screw a until the idle speed is correct oopen and close the throttle a few times to make sure that the idle 69
- Synchronization inspection zx750n 69
- Where the adjusting screw is about to move the pulley 69
- With the engine idling turn the handlebar to both sides 69
- 12 fuel system 70
- Adjusting screws remove the carburetor and check for dirt blockage or throttle valve clearance 70
- Attach the vacuum gauge a to the bolts on the cylinder head 70
- Bottom c of the carburetor bore so that the clearance is the same as the 4 carburetor s clearance using the adjusting screws above 70
- Check idle speed remove th air cleaner housing and the carburetors for the models other than the california model remove the inlet pipe 70
- If the carburetor synchronization cannot be obtained by using the 70
- If the vacuum is incorrect adjust the synchronization 70
- Install the carburetors start the engine and let it idle to measure the carburetor intake vacuum 70
- Loosen the locknuts a and turn the adjusting screws b oturning in the balance adjusting screw closes the throttle valve tighten the locknut 70
- O adjust each clearance a between the throttle valve b and the 70
- Plug a on the 2 cylinder head and install the vacuum gauge bolt 92150 1161 and washer 92022 304 70
- Remove the top covers a do not remove the 4 top cover b 70
- Start the engine and warm it up thoroughly 70
- Synchronization adjustment zx750n 70
- Fuel system 2 13 71
- Synchronization adjustment zx750p 71
- Synchronization inspection zx750p 71
- 14 fuel system 72
- Service fuel level adjustment 72
- Service fuel level inspection 72
- Assemble the carburetor and recheck the fuel level 73
- Bend the tang a on the float arm very slightly to change the float 73
- Carburetor float bowl 73
- Carburetor removal 73
- Check to see if water or dirt comes out tighten the drain plugs 73
- Fuel system 2 15 73
- Fuel system cleanliness inspection 73
- Height increasing the float height lowers the fuel level and decreasing the float height raises the fuel level 73
- If any water or dirt appears during the above inspection clean the fuel 73
- If the fuel level cannot be adjusted by this method the float or the float 73
- Odo not push the needle rod a in during the float height measure 73
- Remove the fuel tank see fuel tank removal connect a suitable hose a to the fitting at the bottom of each 73
- Run the lower ends of the hoses into a suitable container turn out each drain plug b a few turns and drain the float bowls 73
- System see carburetor cleaning and fuel tank cleaning 73
- Valve c is damaged 73
- 16 fuel system 74
- Carburetor disassembly assembly 74
- Carburetor installation 74
- Carburetor cleaning 75
- Carburetor separation assembly 75
- Fuel system 2 17 75
- 18 fuel system 76
- Carburetor inspection 76
- Coolant filter cleaning ar fg fr it kr nl st uk 77
- Fuel system 2 19 77
- High altitude performance adjustment us model 77
- 20 fuel system 78
- Air cleaner 78
- Element removal 78
- Housing installation 78
- Housing removal 78
- Element cleaning and inspection 79
- Element installation 79
- Fuel system 2 21 79
- Oh draining 79
- 22 fuel system 80
- Fuel tank 80
- Fuel tank inspection 80
- Fuel tank installation 80
- Fuel tank removal 80
- Fuel system 2 23 81
- Fuel tank cleaning 81
- Fuel tap installation 81
- Fuel tap removal 81
- 24 fuel system 82
- Fuel tap inspection 82
- Fuel filter removal 83
- Fuel pump fuel filter 83
- Fuel pump installation 83
- Fuel pump removal 83
- Fuel system 2 25 83
- 26 fuel system 84
- Fuel filter inspection 84
- Fuel filter installation 84
- Fuel pump inspection 84
- Fuel system 2 27 85
- Vacuum valve 85
- Vacuum valve inspection 85
- 28 fuel system______________________________________ 86
- Check that the hoses are securely connected replace any kinked deteriorated or damaged hoses 86
- Connect the hoses according to the diagram of the system make sure 86
- Connect the hoses to the separator and install the separator on the 86
- Disconnect the hoses from the liquid vapor separator and remove the 86
- Evaporative emission control system california model only 86
- Fuel system into the running engine or stores the vapors in a canister when the engine is stopped although no adjustments are required a thorough visual inspection must be made at the intervals specified by the periodic maintenance chart 86
- Hose inspection 86
- If the separator has any cracks or is badly damaged replace it with a 86
- Motorcycle 86
- New one 86
- Parts removal installation 86
- Separator from the motorcycle 86
- Separator inspection 86
- Separator operation test 86
- The evaporative emission control system routes fuel vapors from the 86
- The separator perpendicular to the ground 86
- They do not get pinched or kinked 86
- To prevent the gasoline from flowing into or out of the canister hold 86
- Visually inspect the separator for cracks and other damage 86
- ________________________ caution_________________________ 86
- Canister inspection 87
- Fuel system 2 29 87
- Cooling system 89
- Cooling system 3 1 89
- Table of contents 89
- 2 cooling system 90
- Exploded view 90
- Coolant flow chart 91
- Cooling system 3 3 91
- 4 cooling system 92
- Specifications 92
- Check the coolant level in the reserve tank with the motorcycle held 93
- Coolant 93
- Coolant draining 93
- Coolant level inspection 93
- Coolant to the f full level line b 93
- Cooling system 3 5 93
- Drain the coolant from the radiator and engine by removing the drain 93
- If the coolant level is lower than the l low level line a add 93
- Mounting bolts a reserve tank b 93
- O check the level when the engine is cold room or ambient temper 93
- Perpendicular 93
- Place a container under the drain plug a at the bottom of the water 93
- Pump b 93
- Remove 93
- Remove the cap c and pour the coolant into a container 93
- Right inner fairing and lower fairings see frame chapter radiator cap 93
- _______________________ caution________________________ 93
- 6 cooling system 94
- Coolant filling 94
- Cooling system 3 7 95
- Pressure testing 95
- 8 cooling system 96
- Water pump 96
- Water pump inspection 96
- Water pump installation 96
- Water pump removal 96
- Cooling system 3 9 97
- Fan switch leads a radiator hose b 97
- Fuel tank see fuel system chapter upper and lower fairings see frame chapter coolant see coolant draining radiator fan connector a 97
- Radiator hoses a 97
- Radiator mounting bolts a radiator 97
- Radiator radiator fan 97
- Radiator radiator fan removal 97
- Remove 97
- 10 cooling system 98
- Radiator cap inspection 98
- Radiator inspection 98
- Cooling system 3 11 99
- 12 cooling system 100
- Thermostat 100
- Thermostat inspection 100
- Thermostat installation 100
- Thermostat removal 100
- Cooling system 3 13 101
- 14 cooling system ______________________ 102
- Radiator fan switch water temperature sensor 102
- Radiator fan switch water temperature sensor inspection 102
- Radiator fan switch water temperature sensor installation 102
- Radiator fan switch water temperature sensor removal 102
- Engine top end 103
- Engine top end 4 1 103
- Table of contents 4 103
- Engine top end 4 3 105
- 4 engine top end 106
- Specifications 106
- Engine top end 4 5 107
- 6 engine top end 108
- Air suction valve inspection 108
- Clean air system 108
- Vacuum switch valve installation 108
- Vacuum switch valve removal 108
- Vacuum switch valve test 108
- Clean air system hose inspection 109
- Engine top end 4 7 109
- 8 engine top end 110
- Cylinder head cover 110
- Cylinder head cover installation 110
- Cylinder head cover removal 110
- Check that the upper chain guide a bottoms out in the head cover 111
- Engine top end 4 9 111
- Install the washers with the metal side a faces upward tighten the cylinder head cover bolts b 111
- ___________________ caution________________________ 111
- 10 engine top end 112
- Apply a non permanent locking agent to the threads of the tensioner 112
- Camshaft chain tensioner 112
- Camshaft chain tensioner installation 112
- Camshaft chain tensioner removal 112
- Install the spring and washer tighten the cap bolt b 112
- Install the tensioner body so that the stopper faces upward 112
- Mounting bolts a and tighten them 112
- Release the stoppera and push the rod b into the tensioner body 112
- Rem ove 112
- Remove the mounting bolts d and take off the camshaft chain 112
- Seats see frame chapter carburetors see fuel system chapter 3 4 carburetor holders cap bolt a washer b spring c 112
- Tensioner 112
- ________________________ caution________________________ 112
- Camshaft camshaft chain 113
- Camshaft installation 113
- Camshaft removal 113
- Engine top end 4 11 113
- Tlvuine i up end 114
- Camshaft camshaft cap wear 115
- Camshaft chain removal 115
- Camshaft chain wear 115
- Engine top end 4 13 115
- 14 engine top end 116
- Cylinder compression measurement 116
- Cylinder head 116
- Cylinder head removal 116
- Cylinder head installation 117
- Engine top end 4 15 117
- 16 engine top end 118
- Engine top end 4 17 119
- Valve clearance adjustment 119
- Valve clearance inspection 119
- 18 engine top end 120
- And then measure the clearance 120
- Be sure to remeasure the clearance after selecting a shim according to the table the clearance can be out of the specified range because of the shim tolerance 120
- Caution 120
- Column 120
- Example 120
- Exhaust valve 120
- Install the shim specified where the lines intersect this shim will give 120
- Lnstall the shim of this thickness mm 120
- Measure the clearance when engine is cold 2 check present shim size 3 match clearance in vertical column with present shim size in horizontal 120
- Measured clearance is 120
- Olf there is no clearance select a shim which is several sizes smaller 120
- Present shim 120
- Present shim is 120
- Remeasure the valve clearance and readjust if necessary 120
- Replace 120
- Shim with 120
- Specified clearance no change required 120
- The proper clearance 120
- Valve clearance adjustment chart 120
- And then measure the clearance 121
- Be sure to remeasure the clearance after selecting a shim according to the table the clearance can be out of the specified range because of the shim tolerance 121
- Column 121
- Engine top end 4 19 121
- Example 121
- Inlet valve 121
- Install the shim of this thickness mm 121
- Install the shim specified where the lines intersect this shim will give 121
- Measure the clearance when engine is cold 2 check present shim size 3 match clearance in vertical column with present shim size in horizontal 121
- Measured clearance is 121
- O there is no clearance select a shim which is several sizes smaller 121
- Presen rshim f 121
- Present shim is 121
- Remeasure the valve clearance and readjust if necessary 121
- Replace 121
- Shim with 121
- Specified clearance no change required _______ 121
- The proper clearance 121
- Valve clearance adjustment chart 121
- ________________ caution_______________________________ 121
- 20 engine top end 122
- Va ve to guide clearance measurement wobble method 122
- Valve guide installation 122
- Valve guide removal 122
- Valve installation 122
- Valve removal 122
- Carbon white portion of the valve seat with a vernier caliper 123
- Engine top end 4 21 123
- If the manufacturer s instructions are not available use the following 123
- If the outside diameter is too large or too small repair the seat see seat 123
- If the width is too wide too narrow or uneven repair the seat see 123
- Measure the seat width e of the portion where there is no build up 123
- Measuring point is above the guide 123
- O measure the outside diameter d of the seating pattern on the valve 123
- O the reading is not actual valve valve guide clearance because the 123
- Procedure 123
- Remove the valve see valve removal check the valve seating surface a between the valve b and valve 123
- Repair 123
- Repair the valve seat with the valve seat cutters 123
- Seat c 123
- Valve seat inspection 123
- Valve seat repair 123
- 22 engine top end 124
- Engine top end 4 23 125
- Cylinder installation 127
- Cylinder pistons ___________________ 127
- Cylinder removal 127
- Engine top end 4 25 127
- Piston removal 127
- 26 engine top end 128
- Cylinder wear 128
- Piston installation 128
- A thickness gauge a to determine piston ring groove clearance 129
- Check for uneven groove wear by inspecting the ring seating 129
- Engine top end 4 27 129
- If the measurement is under service limit replace the piston 129
- Measure the gap b between the ends of the ring with a thickness 129
- Measure the outside diameter a of each piston 5 mm b up from 129
- Piston must be replaced 129
- Piston ring end gap 129
- Piston ring piston ring groove wear 129
- Piston wear 129
- Place the piston ring a inside the cylinder using the piston to locate 129
- The bottom of the piston at a right angle to the direction of the piston 129
- The ring squarely in place set it close to the bottom of the cylinder where cylinder wear is low 129
- The rings should fit perfectly parallel to groove surfaces if not the 129
- With the piston rings in their grooves make several measurements with 129
- Carburetor holder 130
- Carburetor holder installation 130
- Engine top end 4 29 131
- Muffler installation 131
- Muffler removal 131
- Clutch 133
- Clutch 5 1 133
- Table of contents 133
- 2 clutch 134
- Exploded view 134
- Clutch 5 3 135
- Specifications ________________ _________ ______ ___________ 135
- 4 clutch 136
- Clutch fluid 136
- Clutch fluid change 136
- Fluid level inspection 136
- Bleeding the clutch line 137
- Clutch 5 5 137
- 6 clutch 138
- Clutch master cylinder 138
- Clutch master cylinder disassembly 138
- Clutch master cylinder installation 138
- Clutch master cylinder removal 138
- Clutch 5 7 139
- Clutch master cylinder assembly 139
- Clutch master cylinder inspection visual inspection 139
- 8 clutch 140
- Clutch slave cylinder 140
- Clutch slave cylinder disassembly 140
- Clutch slave cylinder installation 140
- Clutch slave cylinder removal 140
- Clutch 5 9 141
- Clutch slave cylinder assembly 141
- 10 clutch 142
- Clutch 142
- Clutch installation 142
- Clutch removal 142
- Clutch 5 11 143
- 12 clutch 144
- Clutch 5 13 145
- Spring plate free play measurement 145
- 14 clutch 146
- B of the clutch spring plate 146
- Between the highest and lowest gauge readings is the amount of free play 146
- D drive shaft 146
- Engage the cam followers clutch hub with the cams sub clutch 146
- If the free play is not within the usable range change all of the friction 146
- If the free play is not within the usable range change one of the steel 146
- Measure the spring plate free play see spring plate free play 146
- Measurement 146
- Move the clutch housing gear back and forth c the difference 146
- Plates 146
- Plates to a thicker or thinner one to get the correct free play 146
- Spring plate free play adjustment 146
- Temporarily for measurement purpose standard steel plate 146
- To measure the free play set a dial gauge a against the raised center 146
- When replacing all the friction plates do the following install the steel plates and all the new friction plates in the housing 146
- When using all the original clutch plates do the following measure the spring plate free play see spring plate free play 146
- Clutch 5 15 147
- Clutch plate warp inspection 147
- Clutch plate wear damage inspection 147
- Clutch spring free length measurement 147
- Damper cam inspection 147
- If any plate is warped over the service limit replace it with a new one 147
- If any plates show signs of damage replace them with new ones 147
- If any spring is shorter than the service limit it must be replaced 147
- Limiter spring c 147
- Measure the free length of the clutch springs a 147
- Overheating discoloration or uneven wear 147
- Place each friction plate or steel plate on a surface plate and measure 147
- Remove the clutch see clutch removal visually inspect the damper cam a cam follower b and the torque 147
- Replace the part if it appears damaged 147
- The gap between the surface plate a and each friction plate or steel plate b with a thickness gauge c the gap is the amount of friction or steel plate warp 147
- Visually inspect the friction and steel plates for signs of seizure 147
- Engine lubrication system 149
- Engine lubrication system 6 1 149
- Table of contents 149
- Engine lubrication system 6 3 151
- 4 engime lubrication system 152
- Specifications 152
- Engine lubrication system 6 5 153
- Engine oh change 153
- Engine oil and oil filter 153
- Filter change 153
- If the oil has just been changed start the engine and run it for several 153
- Minutes at idle speed this fills the oil filter with oil stop the engine then wait several minutes until the oil settles 153
- Oil to drain down 153
- Pour in the specified type and amount of oil 153
- Remove the engine drain plug a to drain the oil othe oil in the oil filter can be drained by removing the filter see oil 153
- Replace the drain plug gasket with a new one if it is damaged tighten the drain plug 153
- Situate the motorcycle so that it is perpendicular to the ground olf the motorcycle has just been used wait several minutes for all the 153
- Support the motorcycle perpendicular to the ground after warming up 153
- The engine 153
- 6 engine lubrication system 154
- Oil filter change 154
- Engine lubrication system 6 7 155
- Oil cooler 155
- Oil cooler installation 155
- Oil cooler removal 155
- 8 engine lubrication system 156
- Oil pan 156
- Oil pan installation 156
- Oil pan removal 156
- Engine lubrication system 6 9 157
- Oil pump 157
- Oil pump installation 157
- Oil pump removal 157
- 10 engine lubrication system 158
- Oil pressure measurement 158
- Engine lubrication system 6 11 159
- Relief valve 159
- Relief valve inspection 159
- Engine removal 161
- Engine removal installation 161
- Installation 7 1 161
- Table of contents 161
- 2 engine removal installation 162
- Exploded view 162
- 4 engine removal installation 164
- Engine removai lnstallation 164
- Engine removal 164
- Engine installation 165
- Engine removal installation 7 5 165
- Crankshaft transmission 167
- Crankshaft transmission 8 1 167
- Table of contents 167
- 4 crankshaft transmission 170
- Specifications 170
- Crankshaft transmission 8 5 171
- 6 crankshaft transmission 172
- Crankcase assembly 172
- Crankcase splitting 172
- Crankshaft transmission 8 7 173
- 8 crankshaft transmission 174
- Connecting rod installation 174
- Connecting rod removal 174
- Crankshaft and connecting rods 174
- Crankshaft installation 174
- Crankshaft removal 174
- Crankshaft transmission 8 9 175
- 10 crankshaft transmission 176
- Connecting rod big end bearing insert crankpin wear 177
- Crankshaft transmission 8 11 177
- 12 crankshaft transmission 178
- Crankshaft main bearing insert jouma wear 178
- Crankshaft transmission 8 13 179
- 14 crankshaft transmission 180
- C as a set 180
- Crankshaft side clearance 180
- If the clearance exceeds the service limit replace the crankcase halves 180
- Insert a thickness gauge a between the crankcase main bearing and 180
- The crank web at the no 2 journal b to determine clearance 180
- Alternator chain adjustment 181
- Alternator chain alternator shaft starter clutch 181
- Alternator chain removal 181
- ______________________ crankshaft transmission 8 15 181
- 16 crankshaft transmission 182
- Alternator chain installation 182
- Alternator shaft starter clutch removal 182
- Alternator shaft chain wear 183
- Alternator shaft starter clutch installation 183
- Crankshaft transmission 8 17 183
- Starter clutch assembly 183
- Starter clutch disassembly 183
- 18 crankshaft transmission 184
- Chain guide wear 184
- Starter clutch inspection 184
- Crankshaft transmission 8 19 185
- Starter motor idle gear 185
- Starter motor idle gear installation 185
- Starter motor idle gear removal 185
- 20 crankshaft transmission 186
- Externa shift mechanism removal 186
- Shift pedal installation 186
- Shift pedal removal 186
- Transmission 186
- Crankshaft transmission 8 21 187
- External shift mechanism assembly 187
- External shift mechanism installation 187
- 22 crankshaft transmission 188
- Transmission assembly 188
- Transmission disassembly 188
- Transmission shaft installation 188
- Transmission shaft removal 188
- Crankshaft transmission 8 23 189
- Shift drum and fork installation 189
- Shift drum and fork removal 189
- 24 crankshaft transmission 190
- Shift drum assembly 190
- Shift drum disassembly 190
- Crankshaft transmission 8 25 191
- Table of contents 193
- Wheels tires 193
- Wheels tires 9 1 193
- Specifications 195
- Wheels tires 9 3 195
- Additional standard tires zx750p 196
- Warning 196
- 4 wheels tires 198
- Front wheel installation 198
- Front wheel removal 198
- Wheels rims 198
- Rear wheel installation 199
- Rear wheel removal 199
- Wheels tires 9 5 199
- 6 wheels tires 200
- Axle inspection 200
- Balance inspection 200
- Wheel inspection 200
- Balance adjustment 201
- Balance weight installation 201
- Balance weight removal 201
- Wheels tires 9 7 201
- 8 wheels tires 202
- Air pressure inspection adjustment 203
- Tire inspection 203
- Tires ____________________________ ____________ 203
- Wheels tires 9 9 203
- 10 wheels tires 204
- Tire installation 204
- Tire removal 204
- Wheels tires 9 11 205
- 12 wheels tires 206
- Repair 206
- Hub bearing 207
- Hub bearing inspection 207
- Hub bearing installation 207
- Hub bearing removal 207
- I r m l ii al 207
- Llllll 207
- Ui vxwc 207
- Wheels tires 9 13 207
- 14 wheels tires_____________________________ 208
- Disassembly and assembly 208
- Lubrication 208
- Speedometer gear housing 208
- Final drive 209
- Final drive 10 1 209
- Table of contents 209
- 2 final drive 210
- Exploded view 210
- Final drive 10 3 211
- Specifications 211
- 4 final drive 212
- Drive chain 212
- Slack adjustment 212
- Slack inspection 212
- Wheel alignment inspection adjustment 212
- Drive chain wear inspection 213
- Final drive 10 5 213
- Lubrication 213
- 6 final drive 214
- Drive chain installation 214
- Drive chain removal 214
- Chain guard 215
- Chain guard installation 215
- Chain guard removal 215
- Final drive 10 7 215
- 8 final drive 216
- Engine sprocket installation 216
- Engine sprocket removal 216
- Sprocket coupling 216
- Final drive 10 9 217
- Rear sprocket installation 217
- Rear sprocket removal 217
- Rear sprocket warp inspection 217
- Sprocket wear inspection 217
- 10 final drive 218
- Coupling bearing inspection and lubrication 218
- Coupling bearing installation 218
- Coupling bearing removal 218
- Final drive 10 11 219
- Brakes 221
- Brakes 11 1 221
- Table of contents 221
- 2 brakes 222
- Exploded view 222
- 4 brakes 224
- Specifications 224
- Brake pedal 225
- Brake pedal position adjustment 225
- Brake pedal position inspection 225
- Brakes 11 5 225
- 6 brakes 226
- Caliper installation 226
- Caliper removal 226
- Calipers 226
- Front caliper disassembly 226
- Brakes 11 7 227
- Rear caliper disassembly 227
- 8 brakes 228
- Caliper assembly 228
- Brake pads_________________ 229
- Brakes 11 9 229
- Front brake pad installation zx750n 229
- Front brake pad removal zx750n 229
- Front brake pad removal zx750p 229
- 10 brakes 230
- Front brake pad installation zx750p 230
- Rear brake pad installation zx750n 230
- Rear brake pad removal zx750n 230
- Awarning 231
- Brakes 11 11 231
- Check the lining thickness a of the pads in each caliper 231
- If the lining thickness of either pad is less than the service limit b 231
- Install the pad pins and clip b the clip must be outside of the 231
- Install the piston pad cover 231
- Lining wear 231
- Push the caliper pistons in by hand as far as they will go install the brake pads and pad springs a on the original position as 231
- Rear brake pad installation zx750p 231
- Rear brake pad removal zx750p 231
- Replace both pads in the caliper as a set 231
- Unscrew the caliper mounting bolts detach the caliper from the disc remove the piston pad cover a draw out the clip b and take off the pad pin c remove the brake pads d and pad springs e 231
- 12 brakes 232
- Front master cylinder installation 232
- Front master cylinder removal 232
- Master cylinder 232
- Rear master cylinder removal 232
- Brakes 11 13 233
- Front master cylinder disassembly 233
- Rear master cylinder disassembly 233
- Rear master cylinder installation 233
- 14 brakes 234
- Master cylinder assembly 234
- Master cylinder inspection visual inspection 234
- B measuring area 235
- B turn the wheel by hand 235
- Brake disc 235
- Brake disc installation 235
- Brake disc removal 235
- Brake disc warp 235
- Brake disc wear 235
- Brakes 11 15 235
- For front disc inspection turn the handlebar fully to one side set up a dial gauge against the disc a as shown and measure disc 235
- If runout exceeds the service limit replace the disc 235
- If the disc has worn past the service limit replace it 235
- Install the disc on the wheel so that the marked side a faces out tighten the mounting bolts b 235
- Jack up the motorcycle so that the wheel is off the ground 235
- Measure the thickness of each disc a at the point where it has worn 235
- Remove the wheel see wheels tires chapter unscrew the mounting bolts and take off the disc 235
- Runout 235
- The most 235
- 16 brakes 236
- Brake fluid 236
- Brake fluid change 236
- Level inspection 236
- Bleeding the brake line 237
- Brakes 11 17 237
- 18 brakes 238
- Brake hose 239
- Brake hose inspection 239
- Brake hose removal installation 239
- Brakes 11 19 239
- Suspension 241
- Suspension 12 1 241
- Table of contents 241
- 2 suspension 242
- Exploded view 242
- 4 suspension 244
- Specifications 245
- Suspension 12 5 245
- 6 suspension 246
- Compression damping force adjustment 246
- Front fork 246
- Rebound damping force adjustment 246
- X x x x x x 246
- Front fork removal each fork leg 247
- Spring preload adjustment 247
- Suspension 12 7 247
- 8 suspension 248
- Fork oh change zx750n 248
- Front fork installation 248
- Suspension 12 9 249
- 10 suspension 250
- Fork oil change zx750p 251
- Suspension 12 11 251
- 12 suspension 252
- Front fork disassembly zx750n 253
- Suspension 12 13 253
- 14 suspension 254
- Front fork assembly zx750n 254
- Front fork disassembly zx750p 255
- Suspension 12 15 255
- 16 suspension 256
- Front fork assembly zx750f 256
- Dust seal inspection 257
- Inner tube inspection 257
- Spring tension 257
- Suspension 12 17 257
- 18 suspension 258
- Compression damping force adjustment 258
- Rear shock absorber 258
- Rebound damping force adjustment zx750n 258
- Rebound damping force adjustment zx750p 258
- T t t t 258
- X i i x i x 258
- X x x x x 258
- X x x x x x 258
- Î î t t t t 258
- Rear shock absorber removal 259
- Spring preload adjustment 259
- Suspension 12 19 259
- 20 suspension 260
- Awarning 260
- From the gas reservoir 260
- Pack the rocker arm needle bearing with molybdenum disulfide grease tighten the shock absorber nuts 260
- Rear shock absorber installation 260
- Rear shock absorber scrapping 260
- Remove the shock absorber see rear shock absorber removal remove the valve cap a and release the nitrogen gas completely 260
- Remove the valve 260
- Suspension 12 21 261
- Swing arm removal 261
- Swingarm 261
- 22 suspension 262
- Swingarm bearing installation 262
- Swingarm bearing removal 262
- Swingarm installation 262
- Rocker arm installation 263
- Rocker arm removal 263
- Suspension 12 23 263
- Tie rod installation 263
- Tie rod removal 263
- Tie rod rocker arm 263
- 24 suspension 264
- Steering 265
- Steering 13 1 265
- Table of contents 265
- 2 steering 266
- Exploded view 266
- Specifications 267
- Steering 13 3 267
- 4 steering 268
- Steering 268
- Steering adjustment 268
- Steering inspection 268
- Steering 13 5 269
- Steering stem 269
- Stem bearing removal 269
- Stem stem bearing installation 269
- 6 steering 270
- Steering 13 7 271
- Stem bearing lubrication 271
- 8 steering 272
- Handlebar 272
- Handlebar installation 272
- Handlebar removal 272
- Frame 14 1 273
- Table of contents 273
- 2 frame 274
- Exploded view 274
- 4 frame 276
- Frame 14 5 277
- Rear seat installation zx750p 277
- Rear seat removal zx750p 277
- Seat installation zx750n 277
- Seat removal zx750n 277
- 6 frame 278
- Front seat installation zx750p 278
- Front seat removal zx750p 278
- Frame 14 7 279
- Seat cover removal 279
- Seat cover zx750n 279
- 8 frame 280
- Side cover installation 280
- Side cover removal 280
- Side covers zx750p 280
- Fairings 281
- Frame 14 9 281
- Inner fairing installation 281
- Inner fairing removal 281
- Lower fairing removal 281
- Upper fairing removal 281
- 10 frame 282
- Fenders 282
- Front fender removal 282
- Rear fender installation 282
- Rear fender removal 282
- Battery case 283
- Battery case removal 283
- Frame 14 11 283
- 12 frame 284
- Rear frame 284
- Rear frame installation 284
- Rear frame removal 284
- Electrical system 285
- Electrical system 15 1 285
- Table of contents 285
- 2 electrical system 286
- Exploded view 286
- Electrical system 15 3 287
- 4 electrical system 288
- Electrical system 15 5 289
- Specifications 289
- 6 electrical system 290
- Parts location 290
- Electrical system 15 7 291
- Precautions 291
- 8 electrical system 292
- Electrical wiring 292
- Wiring inspection 292
- Battery 293
- Battery charging condition can be checked by measuring battery 293
- Charging condition inspection 293
- Disconnect the battery terminal leads see charging condition 293
- Electrical system 15 9 293
- If the reading is below the specified refreshing charge is required 293
- Inspection 293
- Measure the battery terminal voltage 293
- Measure with a digital voltmete 293
- Place voltage 293
- Refreshing charge 293
- Remove the battery a refresh charge by following method according to the battery terminal 293
- Terminal voltage remove the seats see frame chapter disconnect the battery terminal leads 293
- Voltage 293
- Which can be read one decimal 293
- __________ caution_______________________________ 293
- ______________________ caution_________________ _ 293
- 10 electrical system 294
- Alternator disassembly 295
- Alternator installation 295
- Alternator removal 295
- Alternator______________ __ ________ ___________ _ 295
- Electrical system 15 11 295
- 12 electrical system 296
- Alternator assembly 297
- Electrical system 15 13 297
- 14 electrical system 298
- Electrical system 15 15 299
- Operational inspection 299
- 16 electrical system 300
- Rotor coil inspection 300
- Slip ring cleaning 300
- Stator coil inspection 300
- Carbon brush length 301
- Electrical system 15 17 301
- Rectifier inspection 301
- Regulator inspection 301
- Slip ring diameter 301
- 18 electrical system 302
- Alternator ball bearing inspection 302
- Ec 1 0 2 303
- Electrical system 15 19 303
- 20 electrical system 304
- Ignition system 304
- Pickup coil installation 304
- Pickup coil removal 304
- Electrical system 15 21 305
- Ignition coil installation 305
- Ignition coil removal 305
- Pickup coil inspection 305
- 22 electrical system 306
- Ignition coi inspection 306
- Spark plug removal 306
- Electrical system 15 23 307
- Fit the plug caps securely 307
- Ic igniter inspection 307
- If the gaps are incorrect carefully bend the side electrode b with a 307
- If the tester readings are not as specified replace the ic igniter 307
- In the plug wrench a 307
- Insert the spark plug vertically into the plug hole with the plug installed 307
- Measure the gaps a with a wire type thickness gauge 307
- Remove the side covers see frame chapter remove the ic igniter a and disconnect the connectors set the hand tester to the x 1 kq range and make the measurements 307
- Shown in the table 307
- Spark plug gap inspection 307
- Spark plug installation 307
- Suitable tool to obtain the correct gaps 307
- Tighten the plugs 307
- ________________________ caution______________________ _ 307
- 24 electrical system 308
- Electrical system 15 25 309
- 26 electrical system 310
- Ic igniter troubleshooting 310
- Electrical system 15 27 311
- 28 electrical system 312
- Starter motor 312
- Starter motor installation 312
- Starter motor removal 312
- Electrical system 15 29 313
- Starter motor assembly 313
- Starter motor disassembly 313
- Armature inspection 315
- Brush lead inspection 315
- Brush plate and terminal bolt inspection 315
- Electrical system 15 31 315
- Starter relay inspection 315
- 32 electrical system 316
- Bk y oo bk y 316
- Electrical system 15 33 317
- Headlight beam horizontal adjustment 317
- Headlight beam vertical adjustment 317
- Headlight bulb replacement 317
- Lighting system ___________________ 317
- 34 electrical system 318
- Headlight diode inspection europe models except u k 318
- Electrical system 15 35 319
- 36 electrical system 320
- Electrical system 15 37 321
- Turn signa relay inspection 321
- 38 electrical system 322
- Gyj us cn 322
- Us u s mode l cn canada model 322
- Electrical system 15 39 323
- Fuel pump ______________ ______________________ 323
- Fuel pump operational inspection 323
- Fuel pump relay inspection 323
- Remo vailinstallation 323
- 40 electrical system 324
- Electrical system 15 41 325
- Fan motor inspection 325
- Fan system circuit inspection 325
- Radiator fan system_________________________ 325
- 42 electrical system 326
- Bulb replacement 326
- Meter gauge disassembly 326
- Meter gauge removal 326
- Meters gauge 326
- Tachometer inspection 326
- Electrical system 15 43 327
- 44 electrical system 328
- Water temperature gauge inspection 328
- Brake light timing adjustment 329
- Brake light timing inspection 329
- Electrical system 15 45 329
- Switch inspection 329
- Switches and sensors 329
- 46 electrical system 330
- Radiator fan switch inspection 330
- Throttle switch inspection zx750n 330
- Water temperature sensor inspection 330
- Electrical system 15 47 331
- If the tester does not read as specified the throttle switch is defective o remove the air cleaner housing and replace the throttle switch a 331
- _________________ caution_____________________________ 331
- 48 electrical system 332
- Fuel enficher solenoid valve zx750n 332
- Fuel enricher solenoid valve inspection 332
- Electrical system 15 49 333
- Junction box 333
- Junction box fuse circuit inspection 333
- Starter circuit headlight belay inspection 333
- 50 electrical system 334
- Diode circuit inspection 334
- Electrical system 15 51 335
- 52 electrical system 336
- A main fuse removal 336
- Fuse inspection 336
- Fuse installation 336
- Junction box fuse removal 336
- G 0 gy 338
- Left handlebar switch connections 338
- Zx750n wiring diagram us and canada 338
- Color code 339
- Electrical system 15 53 339
- 54 electrical system_____________ 340
- Zx750n wiring diagram united kingdom 340
- Color code 341
- On switch connections right h a n d l e 0 ar switch connections 341
- Left handlebar switch connections 342
- Zx750n wiring diagram european models except united kingdom 342
- Ai ternator 343
- Color code 343
- Electrical system 15 55 343
- Kkötö 343
- Left handlebar switch connections____________________ 344
- Zx750p wiring diagram us and canada 344
- 98051 1582b c 345
- Color code 345
- Electrical system 15 57 345
- Ifflwtffino 345
- 58 electrical system 346
- Zx750p wiring diagram australia 346
- Color code 347
- Left handlebar switch connections ignition switch conne 348
- Passing button 348
- Zx750p wiring diagram united kingdom 348
- Color code 349
- Electrical system 15 59 349
- 60 electrical system 350
- Dr dr dr 350
- Left handlebar switch connections ignition switc 350
- Zx75op wiring diagram european models except united kingdom 350
- Color code 351
- Right ian l ebar switch connection 351
- Switch c0nnec1 ions 351
- Appendix 353
- Appendix 16 1 353
- Table of contents 353
- 2 appendix 354
- Additional considerations for racing 354
- Carburetor 354
- Spark plug 354
- Appendix 16 3 355
- Spark plug inspection 355
- 4 appendix 356
- Engine doesn t start starting difficulty 356
- Poor running at low speed 356
- Troubleshooting guide 356
- Appendix 16 5 357
- Clutch operation faulty 357
- Over cooling 357
- Overheating 357
- Poor running or no power at high speed 357
- 6 appendix 358
- Abnormal drive train noise 358
- Abnormal engine noise 358
- Abnormal frame noise 358
- Gear shifting faulty 358
- Oil pressure warning light goes on 358
- Appendix 16 7 359
- Battery trouble 359
- Brake doesn t hold 359
- Exhaust smokes excessively 359
- Handling and or stability unsatisfactory 359
- 8 appendix 360
- General lubrication 360
- Lubrication 360
- Appendix 16 9 361
- Nut bolt and fastener tightness_________________ 361
- Tightness inspection 361
- 10 appendix 362
- 40 5 f c 362
- 5 f 40 362
- Prefixes for units 362
- Unit conversion table 362
- Units of force 362
- Units of length 362
- Units of mass 362
- Units of power 362
- Units of pressure 362
- Units of speed 362
- Units of temperature 362
- Units of torque 362
- Units of volume 362
- Part no 99924 1193 03 364
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ENGINE TOP END 4 1 Engine Top End Table of Contents Exploded View 4 2 Specifications 4 4 Clean Air System 4 6 Air Suction Valve Inspection 4 6 Vacuum Switch Valve Removal 4 6 Vacuum Switch Valve Installation 4 6 Vacuum Switch Valve Test 4 6 Clean Air System Hose Inspection 4 7 Cylinder Head Cover 4 8 Cylinder Head Cover Removal 4 8 Cylinder Head Cover Installation 4 8 Camshaft Chain Tensioner 4 10 Camshaft Chain Tensioner Removal 4 10 Camshaft Chain Tensioner Installation 4 10 Camshaft Camshaft Chain 4 11 Camshaft Removal 4 11 Camshaft Installation 4 11 Camshaft Camshaft Cap Wear 4 13 Camshaft Chain Removal 4 13 Camshaft Chain Wear 4 13 Cylinder Head 4 14 Cylinder Compression Measurement 4 14 Cylinder Head Removal 4 14 Cylinder Head Installation 4 15 Valves 4 17 Valve Clearance Inspection 4 17 Valve Clearance Adjustment 4 17 Valve Removal 4 20 Valve Installation 4 20 Valve Guide Removal 4 20 Valve Guide Installation 4 20 Valve to Guide Clearance Measurement Wobble Method 4 20 Valve Seat Inspection 4 21 Valve Seat Repair 4 21 Seat Cutter Operation Care 4 22 Marks Stamped on the Cutter 4 22 Operating Procedures 4 22 Cylinder Pistons 4 25 Cylinder Removal 4 25 Cylinder Installation 4 25 Piston Removal 4 25 Piston Installation 4 26 Cylinder Wear 4 26 Piston Wear 4 27 Piston Ring Piston Ring Groove Wear 4 27 Piston Ring End Gap 4 27 Carburetor Holder 4 28 Carburetor Holder Installation 4 28 Muffler 4 29 Muffler Removal 4 29 Muffler Installation 4 29