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NINJA ZX-7RR (1997-2003)
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Kawasaki NINJA ZX-7RR (1997-2003) [2/364] Read owner s manual before operating

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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

Kawasaki NINJA ZX-7RR (1997-2003) [2/364] Read owner s manual before operating

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