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KAWASAKI NINJA ZX-7R Service Manual

Also See for NINJA ZX-7R

Owner's manual - 53 pages
Service manual - 363 pages

Most useful pages: More

Fuel tank removal/installation/inspection Throttle mechanism Accelerator pumps Valve clearance inspection/adjustment Specifications

364

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Table of Contents

2
List of Abbreviations
3
Quick Reference Guide
5
Emission Control Information
9
General Information
10
Before Servicing
12
Model Identification
12
ZX750-N1 Left Side View
12
ZX750-N1 Right Side View
13
ZX750-N1 (Europe Model) Left Side View
13
ZX750-N1 (Europe Model) Right Side View
14
ZX750-P1 (US and Canada Models) Left Side View
14
ZX750-P1 (US and Canada Models) Right Side View
15
ZX750-P1 (Europe Model) Left Side View
15
ZX750-P1 (Europe Model) Right Side View
16
General Specifications
20
Periodic Maintenance Chart
21
Technical Information - Maintenance Free Battery
22
Filling the Battery With Electrolyte
23
Initial Charge
24
Battery Precautions
24
Interchangeability With Ordinary Battery
25
Throttle Mechanism
25
Accelerator Pumps
25
Technical Information - Flat CR Slide Carburetor
26
Fuel Enricher
27
Technical Information - Side Camshaft Chain
28
Technical Information - Engine Lubrication System
29
Technical Information - Connecting Rod Big End Nut Tightening
32
Technical Information - Swingarm
32
Technical Information - Alternator Unit
33
Torque and Locking Agent
38
Special Tools and Sealant
44
Cable, Wire and Hose Routing
54
Evaporative Emission Control System (California)
57
Fuel System
58
Fuel System Exploded View
64
Fuel System Specifications
66
Throttle Grip and Cables
66
Free Play Inspection
66
Free Play Adjustment
66
Cable Installation
67
Cable Lubrication
68
Choke Cable Free Play Inspection
68
Choke Cable Free Play Adjustment
68
Choke Cable Installation
68
Choke Cable Lubrication
69
Carburetors Idle Speed Inspection
69
Carburetors Idle Speed Adjustment
69
Carburetors Synchronization Inspection
70
Carburetors Synchronization Adjustment
72
Carburetors Service Fuel Level Inspection
72
Carburetors Service Fuel Level Adjustment
73
Carburetors Fuel System Cleanliness Inspection
73
Carburetor Removal
74
Carburetor Installation
74
Carburetor Disassembly/Assembly
75
Carburetor Separation/Assembly
75
Carburetor Cleaning
76
Carburetor Inspection
77
High Altitude Performance Adjustment (US Model)
77
Coolant Filter Cleaning (AR, FG, FR, IT, KR, NL, ST, UK)
78
Air Cleaner Housing Removal
78
Air Cleaner Housing Installation
78
Air Cleaner Element Removal
79
Air Cleaner Element Installation
79
Air Cleaner Element Cleaning and Inspection
79
Air Cleaner Oil Draining
80
Fuel Tank Removal
80
Fuel Tank Installation
80
Fuel Tank Inspection
81
Fuel Tank Cleaning
81
Fuel Tap Removal
81
Fuel Tap Installation
82
Fuel Tap Inspection
83
Fuel Pump Removal
83
Fuel Filter Removal
84
Fuel Filter Installation
84
Fuel Pump Inspection
84
Fuel Filter Inspection
85
Vacuum Valve Inspection
86
Evaporative Emission Control System Parts Removal/Installation
86
Evaporative Emission Control System Hose Inspection
86
Evaporative Emission Control System Separator Inspection
86
Evaporative Emission Control System Separator Operation Test
87
Evaporative Emission Control System Canister Inspection
89
Cooling System
90
Cooling System Exploded View
91
Coolant Flow Chart
92
Cooling System Specifications
93
Coolant Level Inspection
93
Coolant Draining
94
Coolant Filling
95
Pressure Testing
96
Water Pump Removal
96
Water Pump Installation
96
Water Pump Inspection
97
Radiator, Radiator Fan Removal
98
Radiator Inspection
98
Radiator Cap Inspection
100
Thermostat Removal
100
Thermostat Installation
100
Thermostat Inspection
102
Radiator Fan Switch, Water Temperature Sensor Removal
102
Radiator Fan Switch, Water Temperature Sensor Installation
102
Radiator Fan Switch, Water Temperature Sensor Inspection
103
Engine Top End
104
Engine Top End Exploded View
106
Engine Top End Specifications
108
Clean Air System
108
Air Suction Valve Inspection
108
Vacuum Switch Valve Removal
108
Vacuum Switch Valve Installation
109
Clean Air System Hose Inspection
110
Cylinder Head Cover Removal
110
Cylinder Head Cover Installation
112
Camshaft Chain Tensioner Removal
112
Camshaft Chain Tensioner Installation
113
Camshaft Removal
113
Camshaft Installation
115
Camshaft, Camshaft Cap Wear
115
Camshaft Chain Removal
115
Camshaft Chain Wear
116
Cylinder Compression Measurement
116
Cylinder Head Removal
117
Cylinder Head Installation
119
Valve Clearance Inspection
119
Valve Clearance Adjustment
120
Valve Clearance Adjustment Chart
122
Valve Removal
122
Valve Installation
122
Valve Guide Removal
122
Valve Guide Installation
123
Valve Seat Inspection
123
Valve Seat Repair
124
Seat Cutter Operation Care
124
Marks Stamped On the Cutter
127
Cylinder Removal
127
Cylinder Installation
127
Piston Removal
128
Piston Installation
128
Cylinder Wear
129
Piston Wear
129
Piston Ring, Piston Ring Groove Wear
129
Piston Ring End Gap
130
Carburetor Holder Installation
131
Muffler Removal
131
Muffler Installation
133
Clutch
134
Clutch Exploded View
135
Clutch Specifications
136
Clutch Fluid Level Inspection
136
Clutch Fluid Change
137
Bleeding the Clutch Line
138
Clutch Master Cylinder Removal
138
Clutch Master Cylinder Installation
138
Clutch Master Cylinder Disassembly
139
Clutch Master Cylinder Assembly
139
Clutch Master Cylinder Inspection (Visual Inspection)
140
Clutch Slave Cylinder Removal
140
Clutch Slave Cylinder Installation
140
Clutch Slave Cylinder Disassembly
141
Clutch Slave Cylinder Assembly
142
Clutch Removal
142
Clutch Installation
145
Spring Plate Free Play Measurement
146
Spring Plate Free Play Adjustment
147
Clutch Plate, Wear, Damage Inspection
147
Clutch Plate Warp Inspection
147
Clutch Spring Free Length Measurement
147
Damper Cam Inspection
149
Engine Lubrication System
150
Engine Lubrication System Exploded View
151
Engine Oil Flow Chart
152
Engine Lubrication System Specifications
153
Engine Oil Level Inspection
153
Engine Oil Change
154
Engine Oil Filter Change
155
Oil Cooler Removal
155
Oil Cooler Installation
156
Oil Pan Removal
156
Oil Pan Installation
157
Oil Pump Removal
157
Oil Pump Installation
158
Oil Pressure Measurement
159
Relief Valve Inspection
161
Engine Removal/Installation
162
Engine Removal/Installation Exploded View
163
Engine Removal/Installation Specifications
164
Engine Removal
165
Engine Installation
167
Crankshaft/Transmission
168
Crankshaft/Transmission Exploded View
170
Crankshaft/Transmission Specifications
172
Crankcase Splitting
172
Crankcase Assembly
174
Crankshaft Removal
174
Crankshaft Installation
174
Connecting Rod Removal
174
Connecting Rod Installation
177
Connecting Rod Big End Bearing Insert/Crankpin Wear
178
Crankshaft Main Bearing Insert/Journal Wear
180
Crankshaft Side Clearance
181
Alternator Chain Adjustment
181
Alternator Chain Removal
182
Alternator Chain Installation
182
Alternator Shaft, Starter Clutch Removal
183
Alternator Shaft, Starter Clutch Installation
183
Starter Clutch Disassembly
183
Starter Clutch Assembly
183
ALternator Shaft Chain Wear
184
Chain Guide Wear
184
Starter Clutch Inspection
185
Starter Motor Idle Gear Removal
185
Starter Motor Idle Gear Installation
186
Transmission
186
Shift Pedal Removal
186
Shift Pedal Installation
186
External Shift Mechanism Removal
187
External Shift Mechanism Installation
187
External Shift Mechanism Assembly
188
Transmission Shaft Removal
188
Transmission Shaft Installation
188
Transmission Disassembly
188
Transmission Assembly
189
Shift Drum and Fork Removal
189
Shift Drum and Fork Installation
190
Shift Drum Disassembly
190
Shift Drum Assembly
191
Drive Shaft
191
Output Shaft
193
Wheels/Tires
194
Wheels/Tires Exploded View
195
Wheels/Tires Specifications
196
Additional Standard Tires (ZX750P)
198
Front Wheel Removal
199
Rear Wheel Removal
199
Rear Wheel Installation
200
Wheel Inspection
200
Axle Inspection
200
Balance Inspection
201
Balance Adjustment
201
Balance Weight Removal
201
Balance Weight Installation
203
Air Pressure Inspection/Adjustment
203
Tire Inspection
204
Tire Removal
204
Tire Installation
206
Repair
207
Hub Bearing Removal
207
Hub Bearing Installation
207
Hub Bearing Inspection
208
Speedometer Gear Housing Disassembly and Assembly
208
Speedometer Gear Housing Lubrication
209
Final Drive
210
Final Drive Exploded View
211
Final Drive Specifications
212
Drive Chain Slack Inspection
212
Drive Chain Slack Adjustment
212
Wheel Alignment Inspection/Adjustment
213
Drive Chain Wear Inspection
213
Drive Chain Lubrication
214
Drive Chain Removal
214
Drive Chain Installation
215
Chain Guard Removal
215
Chain Guard Installation
216
Engine Sprocket Removal
216
Engine Sprocket Installation
217
Rear Sprocket Removal
217
Rear Sprocket Installation
217
Sprocket Wear Inspection
217
Rear Sprocket Warp Inspection
218
Coupling Bearing Removal
218
Coupling Bearing Installation
218
Coupling Bearing Inspection and Lubrication
221
Brakes
222
Brakes Exploded View
224
Brakes Specifications
225
Brake Pedal Position Inspection
225
Brake Pedal Position Adjustment
226
Caliper Removal
226
Caliper Installation
226
Front Caliper Disassembly
227
Rear Caliper Disassembly
228
Caliper Assembly
229
Front Brake Pad Removal
229
Front Brake Pad Installation
231
Rear Brake Pad Removal
231
Rear Brake Pad Installation
231
Lining Wear
232
Front Master Cylinder Removal
232
Front Master Cylinder Installation
232
Rear Master Cylinder Removal
233
Rear Master Cylinder Installation
233
Front Master Cylinder Disassembly
233
Rear Master Cylinder Disassembly
234
Master Cylinder Assembly
234
Master Cylinder Inspection (Visual Inspection)
235
Brake Disc Removal
235
Brake Disc Installation
235
Brake Disc Wear

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Table of Contents

2
List of Abbreviations
3
Quick Reference Guide
5
Emission Control Information
9
General Information
10
Before Servicing
12
Model Identification
12
ZX750-N1 Left Side View
12
ZX750-N1 Right Side View
13
ZX750-N1 (Europe Model) Left Side View
13
ZX750-N1 (Europe Model) Right Side View
14
ZX750-P1 (US and Canada Models) Left Side View
14
ZX750-P1 (US and Canada Models) Right Side View
15
ZX750-P1 (Europe Model) Left Side View
15
ZX750-P1 (Europe Model) Right Side View
16
General Specifications
20
Periodic Maintenance Chart
21
Technical Information - Maintenance Free Battery
22
Filling the Battery With Electrolyte
23
Initial Charge
24
Battery Precautions
24
Interchangeability With Ordinary Battery
25
Throttle Mechanism
25
Accelerator Pumps
25
Technical Information - Flat CR Slide Carburetor
26
Fuel Enricher
27
Technical Information - Side Camshaft Chain
28
Technical Information - Engine Lubrication System
29
Technical Information - Connecting Rod Big End Nut Tightening
32
Technical Information - Swingarm
32
Technical Information - Alternator Unit
33
Torque and Locking Agent
38
Special Tools and Sealant
44
Cable, Wire and Hose Routing
54
Evaporative Emission Control System (California)
57
Fuel System
58
Fuel System Exploded View
64
Fuel System Specifications
66
Throttle Grip and Cables
66
Free Play Inspection
66
Free Play Adjustment
66
Cable Installation
67
Cable Lubrication
68
Choke Cable Free Play Inspection
68
Choke Cable Free Play Adjustment
68
Choke Cable Installation
68
Choke Cable Lubrication
69
Carburetors Idle Speed Inspection
69
Carburetors Idle Speed Adjustment
69
Carburetors Synchronization Inspection
70
Carburetors Synchronization Adjustment
72
Carburetors Service Fuel Level Inspection
72
Carburetors Service Fuel Level Adjustment
73
Carburetors Fuel System Cleanliness Inspection
73
Carburetor Removal
74
Carburetor Installation
74
Carburetor Disassembly/Assembly
75
Carburetor Separation/Assembly
75
Carburetor Cleaning
76
Carburetor Inspection
77
High Altitude Performance Adjustment (US Model)
77
Coolant Filter Cleaning (AR, FG, FR, IT, KR, NL, ST, UK)
78
Air Cleaner Housing Removal
78
Air Cleaner Housing Installation
78
Air Cleaner Element Removal
79
Air Cleaner Element Installation
79
Air Cleaner Element Cleaning and Inspection
79
Air Cleaner Oil Draining
80
Fuel Tank Removal
80
Fuel Tank Installation
80
Fuel Tank Inspection
81
Fuel Tank Cleaning
81
Fuel Tap Removal
81
Fuel Tap Installation
82
Fuel Tap Inspection
83
Fuel Pump Removal
83
Fuel Filter Removal
84
Fuel Filter Installation
84
Fuel Pump Inspection
84
Fuel Filter Inspection
85
Vacuum Valve Inspection
86
Evaporative Emission Control System Parts Removal/Installation
86
Evaporative Emission Control System Hose Inspection
86
Evaporative Emission Control System Separator Inspection
86
Evaporative Emission Control System Separator Operation Test
87
Evaporative Emission Control System Canister Inspection
89
Cooling System
90
Cooling System Exploded View
91
Coolant Flow Chart
92
Cooling System Specifications
93
Coolant Level Inspection
93
Coolant Draining
94
Coolant Filling
95
Pressure Testing
96
Water Pump Removal
96
Water Pump Installation
96
Water Pump Inspection
97
Radiator, Radiator Fan Removal
98
Radiator Inspection
98
Radiator Cap Inspection
100
Thermostat Removal
100
Thermostat Installation
100
Thermostat Inspection
102
Radiator Fan Switch, Water Temperature Sensor Removal
102
Radiator Fan Switch, Water Temperature Sensor Installation
102
Radiator Fan Switch, Water Temperature Sensor Inspection
103
Engine Top End
104
Engine Top End Exploded View
106
Engine Top End Specifications
108
Clean Air System
108
Air Suction Valve Inspection
108
Vacuum Switch Valve Removal
108
Vacuum Switch Valve Installation
109
Clean Air System Hose Inspection
110
Cylinder Head Cover Removal
110
Cylinder Head Cover Installation
112
Camshaft Chain Tensioner Removal
112
Camshaft Chain Tensioner Installation
113
Camshaft Removal
113
Camshaft Installation
115
Camshaft, Camshaft Cap Wear
115
Camshaft Chain Removal
115
Camshaft Chain Wear
116
Cylinder Compression Measurement
116
Cylinder Head Removal
117
Cylinder Head Installation
119
Valve Clearance Inspection
119
Valve Clearance Adjustment
120
Valve Clearance Adjustment Chart
122
Valve Removal
122
Valve Installation
122
Valve Guide Removal
122
Valve Guide Installation
123
Valve Seat Inspection
123
Valve Seat Repair
124
Seat Cutter Operation Care
124
Marks Stamped On the Cutter
127
Cylinder Removal
127
Cylinder Installation
127
Piston Removal
128
Piston Installation
128
Cylinder Wear
129
Piston Wear
129
Piston Ring, Piston Ring Groove Wear
129
Piston Ring End Gap
130
Carburetor Holder Installation
131
Muffler Removal
131
Muffler Installation
133
Clutch
134
Clutch Exploded View
135
Clutch Specifications
136
Clutch Fluid Level Inspection
136
Clutch Fluid Change
137
Bleeding the Clutch Line
138
Clutch Master Cylinder Removal
138
Clutch Master Cylinder Installation
138
Clutch Master Cylinder Disassembly
139
Clutch Master Cylinder Assembly
139
Clutch Master Cylinder Inspection (Visual Inspection)
140
Clutch Slave Cylinder Removal
140
Clutch Slave Cylinder Installation
140
Clutch Slave Cylinder Disassembly
141
Clutch Slave Cylinder Assembly
142
Clutch Removal
142
Clutch Installation
145
Spring Plate Free Play Measurement
146
Spring Plate Free Play Adjustment
147
Clutch Plate, Wear, Damage Inspection
147
Clutch Plate Warp Inspection
147
Clutch Spring Free Length Measurement
147
Damper Cam Inspection
149
Engine Lubrication System
150
Engine Lubrication System Exploded View
151
Engine Oil Flow Chart
152
Engine Lubrication System Specifications
153
Engine Oil Level Inspection
153
Engine Oil Change
154
Engine Oil Filter Change
155
Oil Cooler Removal
155
Oil Cooler Installation
156
Oil Pan Removal
156
Oil Pan Installation
157
Oil Pump Removal
157
Oil Pump Installation
158
Oil Pressure Measurement
159
Relief Valve Inspection
161
Engine Removal/Installation
162
Engine Removal/Installation Exploded View
163
Engine Removal/Installation Specifications
164
Engine Removal
165
Engine Installation
167
Crankshaft/Transmission
168
Crankshaft/Transmission Exploded View
170
Crankshaft/Transmission Specifications
172
Crankcase Splitting
172
Crankcase Assembly
174
Crankshaft Removal
174
Crankshaft Installation
174
Connecting Rod Removal
174
Connecting Rod Installation
177
Connecting Rod Big End Bearing Insert/Crankpin Wear
178
Crankshaft Main Bearing Insert/Journal Wear
180
Crankshaft Side Clearance
181
Alternator Chain Adjustment
181
Alternator Chain Removal
182
Alternator Chain Installation
182
Alternator Shaft, Starter Clutch Removal
183
Alternator Shaft, Starter Clutch Installation
183
Starter Clutch Disassembly
183
Starter Clutch Assembly
183
ALternator Shaft Chain Wear
184
Chain Guide Wear
184
Starter Clutch Inspection
185
Starter Motor Idle Gear Removal
185
Starter Motor Idle Gear Installation
186
Transmission
186
Shift Pedal Removal
186
Shift Pedal Installation
186
External Shift Mechanism Removal
187
External Shift Mechanism Installation
187
External Shift Mechanism Assembly
188
Transmission Shaft Removal
188
Transmission Shaft Installation
188
Transmission Disassembly
188
Transmission Assembly
189
Shift Drum and Fork Removal
189
Shift Drum and Fork Installation
190
Shift Drum Disassembly
190
Shift Drum Assembly
191
Drive Shaft
191
Output Shaft
193
Wheels/Tires
194
Wheels/Tires Exploded View
195
Wheels/Tires Specifications
196
Additional Standard Tires (ZX750P)
198
Front Wheel Removal
199
Rear Wheel Removal
199
Rear Wheel Installation
200
Wheel Inspection
200
Axle Inspection
200
Balance Inspection
201
Balance Adjustment
201
Balance Weight Removal
201
Balance Weight Installation
203
Air Pressure Inspection/Adjustment
203
Tire Inspection
204
Tire Removal
204
Tire Installation
206
Repair
207
Hub Bearing Removal
207
Hub Bearing Installation
207
Hub Bearing Inspection
208
Speedometer Gear Housing Disassembly and Assembly
208
Speedometer Gear Housing Lubrication
209
Final Drive
210
Final Drive Exploded View
211
Final Drive Specifications
212
Drive Chain Slack Inspection
212
Drive Chain Slack Adjustment
212
Wheel Alignment Inspection/Adjustment
213
Drive Chain Wear Inspection
213
Drive Chain Lubrication
214
Drive Chain Removal
214
Drive Chain Installation
215
Chain Guard Removal
215
Chain Guard Installation
216
Engine Sprocket Removal
216
Engine Sprocket Installation
217
Rear Sprocket Removal
217
Rear Sprocket Installation
217
Sprocket Wear Inspection
217
Rear Sprocket Warp Inspection
218
Coupling Bearing Removal
218
Coupling Bearing Installation
218
Coupling Bearing Inspection and Lubrication
221
Brakes
222
Brakes Exploded View
224
Brakes Specifications
225
Brake Pedal Position Inspection
225
Brake Pedal Position Adjustment
226
Caliper Removal
226
Caliper Installation
226
Front Caliper Disassembly
227
Rear Caliper Disassembly
228
Caliper Assembly
229
Front Brake Pad Removal
229
Front Brake Pad Installation
231
Rear Brake Pad Removal
231
Rear Brake Pad Installation
231
Lining Wear
232
Front Master Cylinder Removal
232
Front Master Cylinder Installation
232
Rear Master Cylinder Removal
233
Rear Master Cylinder Installation
233
Front Master Cylinder Disassembly
233
Rear Master Cylinder Disassembly
234
Master Cylinder Assembly
234
Master Cylinder Inspection (Visual Inspection)
235
Brake Disc Removal
235
Brake Disc Installation
235
Brake Disc Wear

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This manual is also suitable for:

Ninja zx-7rr Zx750-n1 Zx750-n2 Zx750-p1 Zx750-p2 Zx750-p3 ... Show all

Comments to this Manuals

Latest comments:

Jason R Mar 02, 2016 04:42:

I first want to thank you for all the timely and efficient work in developing this website. I have been studying the manual for the Kawasaki Ninja zx7r. What year motorcycle does the manual pertain to. Will this manual give the proper instructions for a 2002 model?
santiago Feb 13, 2015 04:56:

muy bueno el aporte

very god, thank you for information