Cylinder Compression Measurement

OUse the battery which is fully charged. Warm up the engine thoroughly. Seats (see Frame chapter) Fuel Tank (see Fuel System (DFI) chapter) Stick Coils Spark Plugs Owner's Tool - Spark Plug Wrench, 16 mm 92110-1146 Attach the compression gauge A and adapter B firmly into the spark plug hole. OUsing the starter motor, turn the engine over with the throttle fully open until the compression gauge stops rising the compression is the highest reading obtainable. Special Tools-Compression Gauge...

Special Tools and Sealant

Valve Guide Reamer, 04 Valve Seat Cutter, 60 - 025 Valve Seat Cutter Holder, 04 57001-1275 Compression Gauge Adapter, M10 * 1.0 57001-1317 Valve Seat Cutter, 60 - 027 57001-1409 Valve Seat Cutter Holder, 04 57001-1275 Valve Seat Cutter, 60 - 027 57001-1409 Spark Plug Wrench (Owner's Tool) 92110-1146 Spark Plug Wrench (Owner's Tool) 92110-1146 Kawasaki Bond (Silicone Sealant) 56019-120 Compression Gauge Adapter, M10 * 1.0 57001-1317 Kawasaki Bond (Silicone Sealant) 56019-120

Front Fork Disassembly

Remove the front fork see Front Fork Removal . Remove the top plug A with O-ring, take out the collar B , spring seat C , and spring D . Drain the fork oil see Fork Oil Change . Remove the Allen bolt C from the bottom of the fork. Special Tools - Fork Cylinder Holder Handle 57001 -183 D Fork Cylinder Holder Adapter 57001-1057 E OHold the outer tube in a vise A , stop the cylinder unit B from turning by using the special tools, and unscrew the Allen bolt.

Caution

57001 1394

Incorrect, reverse connection or short circuit by needle adapters could damage the DFI or electrical system parts. OAfter measurement, remove the needle adapters and apply silicone sealant to the seals A of the connector B for waterproofing. Silicone Sealant Kawasaki Bond 56019-120 - Seals of Connector Always check battery condition before replacing the DFI parts. A fully charged battery is a must for conducting accurate tests of the DFI system. Trouble may involve one or in some cases all...

Fuel Injectors

57001 1457

Refer to the Throttle Body Assy Disassembly Assembly. Apply the tip of a screwdriver A to the injector C . Put the grip end onto your ear, and listen whether the injector is clicking or not. OA sound scope B can also be used. Do the same for the other injectors. If all the injectors click at a regular intervals, the injectors are good. The trouble may be related to the fuel line, requiring fuel pressure inspection see Fuel Line section in this chapter . OThe click interval becomes shorter as...

FI Indicator LED Light Inspection Flow Chart

Does the LED light go off after 1 2 seconds Does the LED light go off after 10 20 seconds. No Flashes once then goes off or unlit Repair or replace the meter or wiring. DFI and ignition systems are considered to be normal. DFI and ignition systems are abnormal. End of inspection Go to self-diagnosis. DFI and ignition systems are normal. Ask the rider if the problem occurs again.

Technical Information Air Inlet System

Injection System Kawasaki Z750

The ZR750-J1 employs large bore throttle bodies to increase power output. However, sudden changes in throttle opening can cause hesitation and jerky throttle response with a single butterfly valve in a large bore. Therefore two throttle valves are placed in each inlet tract, the main throttle valve located closest to the cylinder and a subthrottle valve placed further up the inlet tract. The main throttle valve is operated by the rider when the throttle grip is turned clockwise or...

Troubleshooting the DFI System

Year of initial registration fine, cloudy, rain, snow, always, other hot, warm, cold, very cold, always street, highway, mountain road uphill, downhill , bumpy, pebble normal, high about 1000 m or more Motorcycle conditions when problem occurred. light up immediately after ignition SW ON, and goes off after 1 2 seconds normal lights blinks immediately after ignition SWON, and stays on DFI problem lights up immediately after ignition SWON, but goes off after...

Subthrottle Valve Actuator Service Code 62

OBe sure the battery is fully charged. Turn the ignition switch OFF. Remove the throttle body assy see Throttle Body Assy Removal . Connect the peak voltage adapter A and a digital meter B to the connector C , using the needle adapter set D . Recommended Tool - Peak Voltage Adapter Special Tool - Needle Adapter Set 57001-1457 Subthrottle Valve Actuator Input Voltage Connections to Harness Connector I Meter BK BL lead 1 Meter - P BL lead 2 II Meter Glead 3 Meter - W BL lead 4 Measure the...

Periodic Maintenance Procedures

Check the throttle grip free play A . If the free play is incorrect, adjust the throttle cable. Throttle Grip Free Play Standard 2 3mm 0.08 0.12 in. Check that the throttle grip moves smoothly from close to full open, and the throttle closes quickly and completely in all steering positions by the return spring. If the throttle grip doesn't return properly, check the throttle cable routing, grip free play, and cable damage. Then lubricate the throttle cable. Run the engine at the idle speed,...

Vehicledown Sensor Service Code 31

Ignition Switch b. Vehicle-down Sensor d. Starter Relay f. Sealed Battery j. Joint Connector B k. Main Fuse 30 A Subthrottle Sensor Removal Adjustment Do not remove or adjust the subthrottle sensor A since it has been adjusted and set with precision at the factory. Never drop the sensor, especially on a hard surface. Such a shock to the sensor can damage it. Subthrottle Sensor Connector black B Input Voltage Inspection OBe sure the battery is fully charged. Turn the...

Warning

Change the brake fluid in the brake line completely if the brake fluid must be refilled but the type and brand of the brake fluid that is already in the reservoir are unidentified. After changing the fluid, use only the same type and brand of fluid thereafter. Recommended Disc Brake Fluid Grade DOT4 Follow procedure below to rear brake fluid reservoir cap correctly. OFirst, tighten the rear brake fluid reservoir cap B clockwise C by hand until slight resistance...

FI Indicator LED Light

Kawasaki Z750 Battery Installation

Remove the meter unit see Electrical System chapter . Using two auxiliary leads, supply battery power to the FI indicator LED light A . BR W Lead Terminal 1 ofthe Meter Battery Terminal BR RLead Terminal 6 ofthe Meter Battery - Terminal Criterion The LED light should light. If the LED light does not go on, replace the meter unit. T. Ignition Switch U. FI Indicator LED Light X. Ignition Fuse 10 A Y. Junction Box d. Starter Relay f. Sealed Battery k. Main Fuse 30 A

Subthrottle Sensor Service Code

Kawasaki Z750 Subthrottle Sensor

Remove the throttle body assy see Throttle Body Assy Removal . Measure the output voltage at the subthrottle sensor in the same way as input voltage inspection. Note the following. Disconnect the subthrottle sensor black A and black connect the harness adapter B between these connectors. Special Tool - Throttle Sensor Harness Adapter 57001-1538 Measure the output voltage of the sensor with the engine stopped, and with the connector joined. Turn the ignition switch ON. Measure the output...

Subthrottle Valve Actuator Service Code

Do not remove the subthrottle valve actuator A since it has been adjusted and set with precision at the factory. Never drop the actuator , especially on a hard surface. Such a shock to the actuator can damage it. OBe sure the battery is fully charged. Turn the ignition switch ON and ensure that the actuator valves open and close make light sounds several times within seconds, and then close at the idle throttle opening position. Turn the ignition switch OFF. If the actuator does not work as...

Stick Coils 1 2 3 4 Service Code 51 52 53

Stick Coil 1 Ignition Stick Coil 2 Ignition Stick Coil 3 Ignition Stick Coil 4 Ignition Coil Service Code 51 Coil Service Code 52 Coil Service Code 53 Coil Service Code 54 Never drop the stick coils, especially on a hard surface. Such a shock to the stick coil can damage it. See the Ignition System section in the Electrical System chapter. OBe sure the battery is fully charged. Turn the ignition switch OFF. Remove the ECU see this chapter . Do not disconnect the ECU connector. Connect a digital...

Note

OThe output voltage changes according to the local atmospheric pressure. Measure the output voltage at the ECU in the same way as input voltage inspection. Note the following. Inlet Air Pressure Sensor Output Voltage Connections to ECU Meter Y BL lead terminal 17 Meter - BR BK lead terminal 14 3.74 4.26 V DC at the standard atmospheric pressure 101.32 kPa, 76 cmHg abs. Turn the ignition switch OFF. If the output voltage is within the usable range, check the ECU for its ground, and power supply...

Resistance Inspection

Disconnect the main throttle sensor connector. Connect a digital meter A to the main throttle sensor connector B . Measure the main throttle sensor resistance. Main Throttle Sensor Resistance Connections BL lead C Standard 4 6kQ if the reading is out of the range, replace the throttle body assy. If the reading is within the range, but the problem still exists, replace the ECU see this chapter . I. Main Throttle Sensor m. Throttle Body Assy Connector I. Main...

Poor Running or No Power at High Speed

Spark plug dirty, broken or maladjusted Clean spark plug and adjust plug gap see chapter 2 . Inspect stick coil see chapter 16 . Spark plug cap shorted or not in good contact Reinstall or inspect stick coil see chapter 16 . Replace it with the correct plug see chapter 16 . Air cleaner clogged, poorly sealed or missing Clean element or inspect sealing see chapter 3 . Change fuel. Inspect and clean fuel system see chapter 3 . Fuel pump operates intermittently and often ECU fuse blows. Pump...

Spark Plug Inspection

Fuel Tank see Fuel System DFI chapter Unscrew the thermostat bracket bolt A . Water Temperature Sensor Connector B Left Switch Housing Connector C OIf removing the spark plug 2 or 3. Pull out the stick coil 1 B . Take out the camshaft position sensor connector C from the bracket. Pull out the stick coil 2 D .

Inlet Air Pressure Sensor Service Code 12 Pv 55 86 cmHg

Cbr Inlet Pressure

Vv Inlet Air Pressure Sensor Output Voltage V Digital Meter Reading Pv Throttle Vacuum Pressure absolute Ps Standard Atmospheric Pressure absolute ST Standard of Sensor Output Voltage v UR Usable Range of Sensor Output Voltage v UR Usable Range of Sensor Output Voltage v

Basic Torque for General Fasteners

Throttle body assy holder clamp bolts Cylinder head bolts M10 used bolts Throttle body assy holder clamp bolts Front camshaft chain guide bolt upper Front camshaft chain guide bolt lower Camshaft chain tensioner mounting bolts Rear master cylinder push rod locknut Rear shock absorber nuts upper and lower

Crankshaft Sensor Inspection

OThe crankshaft sensor has no power source, and when the engine stops, the crankshaft sensor generates no signals. Crank the engine and measure the peak voltage of the crankshaft sensor see Electrical System chapter in order to check the sensor. Check the wiring for continuity, using the following diagram. Start the engine and switch the diagnosis mode to Dealer 1 mode to know all the problem that the DFI system has at the time of self-diagnosis. If the engine cannot be started, the...

Camshaft Position Sensor Removal Installation

The camshaft position sensor detects the position of the camshaft, and distinguishes the cylinder. See the Ignition system section in the Electric System chapter. Camshaft Position Sensor Inspection OThe camshaft position sensor has no power source, and when the engine stops, the camshaft position sensor generates no signal. Crank the engine and measure the peak voltage of the camshaft position sensor see Electrical System chapter in order to check the sensor. Check the wiring for continuity,...

How to Read Service Codes

OService codes are shown by a series of long and short blinks of the FI indicator LED light as shown below. ORead 10th digit and unit digit as the FI indicator LED light blinks. OWhen there are a number of problems, all the service codes can be stored and the display will begin starting from the lowest number service code in the numerical order. Then after completing all codes, the display is repeated until the self-diagnosis indicator terminal is open. Olf there is no problem, no code and...

Table of Contents

Periodic Maintenance Torque and Locking Special Periodic Maintenance Procedures 2-13 Fuel System Idle Speed Air Cleaner Element Cleaning 2-18 Cooling Coolant Engine Top End Air Suction Valve Inspection 2-22 Valve Clearance Inspection 2-22 Clutch Adjust Engine Lubrication Engine Oil Oil Filter Tire Wear Air Pressure Final Drive Chain Slack Inspection 2-27 Drive Chain Slack Adjustment 2-27 Drive Chain Wear Inspection 2-28 Drive Chain Brake Pad Wear Inspection 2-29 Caliper Fluid Seal Damage 2-30...

Backups

OThe ECU takes the following measures to prevent engine damage when the DFI or the ignition system parts have troubles. Output Signal Usable Range or Criteria Main Throttle Sensor Output Voltage 0.2 4.8 V If the main throttle sensor system fails the signal is out of the usable range, wiring short or open , the ECU locks ignition timing into the ignition timing at closed throttle position and sets the DFI in the D-J method. Also, the main throttle sensor system and inlet air pressure fails, the...

Special Tools

57001 1400	Adapter Sensor

Throttle Sensor Setting Adapter 57001-1400 Throttle Sensor Setting Adapter 57001-1538 Throttle Sensor Setting Adapter 57001-1538 Kawasaki Bond Silicone Sealant 56019-120 Throttle Sensor Setting Adapter 57001-1400 Kawasaki Bond Silicone Sealant 56019-120 Fuel Pressure Gauge Adapter 57001-1417 DFI Servicing Precautions There are a number of important precautions that should be followed servicing the DFI system. OThis DFI system is designed to be used with a 12 V sealed battery as its power...

Steering

Jack 57001 1238

Lift the front wheel off the ground using the jack. Special Tool - Jack 57001-1238 With the front wheel pointing straight ahead, alternately tap each end of the handlebar. The front wheel should swing fully left and right from the force of gravity until the fork hits the stop. If the wheel binds or catches before the stop, the steering is too tight. Feel for steering looseness by pushing and pulling the forks. If you feel looseness, the steering is too loose. OThe cables and wiring will have...

Engine Doesnt Start Starting Difficulty

Ignition and engine stop switches not ON Starter lockout switch or neutral switch trouble Inspect and charge see chapter 16 . Starter relays not contacting or operating Inspect the starter relay see chapter 16 . Inspect and replace see chapter 16 . Starter system wiring open or shorted Inspect the wiring see chapter 16 . Inspect and replace see chapter 16 . Inspect and repair or replace see chapter 16 . Inspect and replace see chapter 16 . Starter motor rotating but engine doesn't turn over...

Fuel System DFI

Kawasaki Z750 Parts Diagrams

DFI Wiring Special DFI Servicing DFI Servicing Troubleshooting the DFI Inquiries to Inquiries to DFI System Troubleshooting DFI System Troubleshooting Self-diagnosis Self-diagnosis Self-diagnosis Self-diagnosis Service Code Clearing Service Code Clearing How to Read Service How to Read Service How to Erase Service How to Erase Service Service Code Service Code Main Throttle Sensor Service Code Main Throttle Sensor Input Voltage Output Voltage Resistance Inlet Air Pressure Sensor Service Code...

Engine Lubrication System

Kawasaki Z750 Oil

Situate the motorcycle so that it is vertical after warming up the engine. Remove the engine oil drain bolt A to drain the oil. OThe oil in the oil filter can be drained by removing the filter Replace the drain bolt gasket B with a new one. Torque - Engine Oil Drain Bolt 20 N m 2.0 kgf m, 14 ftlb Pour in the specified type and amount of oil. 3.1 L 3.3 US qt when filter is not removed 3.3 L 3.5 US qt when filter is removed 3.8 L 4.0 US qt when engine is completely dry

Kawasaki Z750 Reserve Tank

Kawasaki Z750 Coolant Check

To avoid burns, do not remove the radiator cap or try to change the coolant when the engine is still Coolant on tires will make them slippery and can Since coolant is harmful to the human body, do not Place a container under the water pump drain bolt A , then remove the drain bolt. Remove the fuel tank see Fuel System DFI chapter . Remove the radiator cap A in two steps. First turn the cap counterclockwise to the first stop. Then push and turn it further in the same direction and remove the...

Engine Top

Hero Honda Valve Clearance

Remove the air suction valve see Engine Top End chapter . Visually inspect the reeds for cracks, folds, warps, heat damage or other damage. lf there is any doubt as to the condition of the reeds A , replace the air suction valve as an assembly. Check the reed contact areas B of the valve holder for grooves, scratches, any signs of separation from the holder or heat damage. If there is any doubt as to the condition of the reed contact areas, replace the air suction valve as an assembly. If any...

Technical Information Tail Brake Lights Employing LED

Kawasaki Z750

The emitting color differs according to the materials of semi-conductors. Materials of Semi-Conductor and Emitting Color Materials of Semi-Conductor and Emitting Color P Phosphorus N Nitrogen Al Aluminum Technical Information - KAWASAKI LOW EXHAUST EMISSION SYSTEM Since the emission regulations become more severe, Kawasaki has adopted a type of simplified KAWASAKI LOW EXHAUST EMISSION SYSTEM KLEEN , which have no catalyst protection system, according to each regulation of different countries....

General Specifications

79 kW 107 PS 10 500 r min rpm , MY, AU 80 kW 109 PS 11 000 r min rpm HR 78.2 kW 106 PS 11 000 r min rpm 75 Nm 7.6 kgfm, 55 ftlb 8 200 r min rpm , HR 73 N m 7.4 kgf m, 54 ft lb 8 200 r min rpm FI Fuel Injection KEIHIN TTK34 x 4 Electronically advanced digital igniter From 10 BTDC 1 100 r min rpm to 37 BTDC 5 800 r min rpm 6-speed, constant mesh, return shift 12 V 0.5 3.8 W LED , CA 12 V 0.5 5W LED Specifications are subject to change without notice, and may not apply to every country. AU...