Kawasaki NINJA ZX-7RR (1997-2003) [129/364] Engine top end 4 27

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 27 Piston Wear Measure the outside diameter A of each piston 5 mm B up from the bottom of the piston at a right angle to the direction of the piston pin If the measurement is under service limit replace the piston Piston Diameter Standard 72 942 72 958 mm Service Limit 72 8 mm Piston Ring Piston Ring Groove Wear Check for uneven groove wear by inspecting the ring seating The rings should fit perfectly parallel to groove surfaces If not the piston must be replaced With the piston rings in their grooves make several measurements with a thickness gauge A to determine piston ring groove clearance Piston Ring Groove Clearance Standard Top 0 05 0 09 mm Second 0 03 0 07 mm Service Limit 0 19 mm 0 17 mm Piston Ring End Gap Place the piston ring A inside the cylinder using the piston to locate the ring squarely in place Set it close to the bottom of the cylinder where cylinder wear is low Measure the gap B between the ends of the ring with a thickness gauge Piston Ring End Gap Top Second Standard 0 20 0 35 mm 0 40 0 55 mm Service Limit 0 65 mm 0 85 mm