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Assembly & Preparation


Table of Contents

   Summary of Contents for Kawasaki Z750R

  • Page 1 Z750R Z750R ABS Motorcycle Assembly & Preparation Manual...
  • Page 3 Kawasaki and their Kawasaki Dealers. This Assembly and Preparation Manual ex- plains step by step procedures of the following NOTICE items for all Kawasaki Z750R and Z750R ABS. NOTICE is used to address practices not related to personal injury. 1. Uncrating 2.
  • Page 4: Table Of Contents

    Table of Contents Uncrating ..................Opening Crate ................Parts Check ................. Assembly ..................Handlebar..................Handlebar Weight................ Clutch Cable................Rear View Mirrors (Left and Right) ..........Seat Under Cover................ Preparation ................... Battery Service ................Coolant ..................Front Brake Fluid................. Rear Brake Fluid ................. Brake Disc Cleaning ..............
  • Page 5: Uncrating

    UNCRATING 3 • Uncrating First, remove the lower bolts (D = 12, L = 16) (2) at the handlebar holder and discard them. • Remove the upper bolts (D = 8, L = 12) (2) to Opening Crate take off the crate bracket and discard them. WARNING Crates have sharp edges and may have nails or screws that can cause cuts and...
  • Page 6 4 UNCRATING A. Rubber Band B. Protective Cover...
  • Page 7: Parts Check

    ASSEMBLY 5 Parts Check • Open the parts box, and check the parts against the illustrations. There may be minor differences between these illustrations and the actual vehicle parts. In the following charts under Remarks, D = diameter in millimeters, and L = length in millimeters. Part Name Remarks Weight, Handlebar...
  • Page 8: Handlebar Weight

    6 ASSEMBLY A.Top Handlebar Clamp A. Handlebar Weight (Right) B.Handlebar Clamp Bolts (D = 8, L = 30) B. Screw (D = 8, L = 45) C.Punched Mark D.No Gap Clutch Cable E. Gap • Apply a light coat of grease on the clutch inner Handlebar Clamp Bolt Tightening cable.
  • Page 9: Rear View Mirrors (left And Right)

    ASSEMBLY 7 A. Clutch Cable A. Lower Hexagonal Area for Tightening B. Left Switch Housing Harness B. Upper Hexagonal Area (Adapter) C. Cable/Wiring Clamp (Steel) C. Rubber Boot • • Fasten the clutch cable and switch housing Reinstall the rubber boot. •...
  • Page 10: Preparation

    8 PREPARATION Preparation Battery Service Battery Removal The battery used in this motorcycle is a sealed type and never needs to be refilled. Follow the procedure for activating a new battery to ensure the best possible battery performance. • Insert the ignition key into the seat lock lo- cated under the left seat cover (rear fairing).
  • Page 11: Battery Activation

    PREPARATION 9 NOTICE Do not remove the aluminum sealing sheet from the filler ports until just prior to use. Be sure to use the dedicated electrolyte container for correct elec- trolyte volume. • Place the battery on a level surface. •...
  • Page 12 10 PREPARATION A. Strip of Caps A. Air Bubbles B. Sealed Cells B. Tap the Container • • Place the electrolyte container upside down Keep the container in place. Don’t remove the container from the battery, the battery re- with the six sealed cells into the filler ports of the battery.
  • Page 13: Battery Installation

    Standard Charge: 0.9 A × 5 ∼ 10 hours • If using a recommended battery charger, fol- low the charger’s instructions for newly acti- vated sealed battery. Kawasaki-recommended chargers: Battery Mate 150-9 OptiMate PRO 4-S/PRO S/PRO 2 Yuasa MB-2040/2060 Christie C10122S •...
  • Page 14: Coolant

    12 PREPARATION A. Battery A. Reserve Tank B. Positive Cable (+) B. F (Full) Level Line C. Negative Cable (–) C. L (Low) Level Line D. Route the (+) cable through the guide D. Seat Cover (Right) in the battery case. •...
  • Page 15 PREPARATION 13 Screw Rivet Removal A. Right Side Cover A. Screw Rivet B. Bolt (D = 5, L = 16) and Flat Washer (D = 20) B. Central Pin C. Projections C. Turn the screw rivet. • Remove the mounting bolt (D = 6, L = 14) and Screw Rivet Installation the screw rivets (2) from the right seat cover (rear fairing).
  • Page 16 14 PREPARATION • Install the cap. • Insert the projections of the right seat cover into the grommets. A. Fuse Box B. Seat Bracket C. Passenger’s Seat Lock Cable A. Cap D. Rider’s Seat Lock Cables B. Seat Cover (Right) E.
  • Page 17: Front Brake Fluid

    PREPARATION 15 NOTE ○ If there is difficulty removing the ignition key from the seat lock, turn it lightly counterclock- wise while pulling it out. Front Brake Fluid Front Brake Fluid Level Inspection • With the front brake fluid reservoir held hor- izontal, check that the fluid level is between the upper and lower level lines.
  • Page 18 16 PREPARATION • WARNING Attach a clear plastic hose to the bleed valve on the front master cylinder and run the other Brake fluid that is contaminated by end of the hose into a container. moisture or dirt, mixed or contains air •...
  • Page 19: Rear Brake Fluid

    PREPARATION 17 A. Hold the brake lever applied. A. Reservoir Cap Stopper Screw B. Quickly open and close the bleed valve B. Upper Level Line on the front brake caliper. C. Lower Level Line C. Release the brake lever. D. Rear Brake Fluid Reservoir •...
  • Page 20: Brake Disc Cleaning

    18 PREPARATION • • Operate the brake pedal several times. When air bleeding is finished, check that the • If it feels spongy, there might be air in the fluid level is between the upper and lower brake line. level lines. •...
  • Page 21: Drive Chain

    PREPARATION 19 Drive Chain Drive Chain Slack and Wheel Alignment Inspection • Set the motorcycle up on its side stand. • Make sure that the drive chain has the speci- fied amount of play, and that the left and right notches are on the same marks or points on the left and right of the swingarm.
  • Page 22 20 PREPARATION • Tighten both chain adjuster locknuts. • Tighten the rear axle nut to the specified torque. Torque: 108 N·m (11.0 kgf·m, 80 ft·lb) • Rotate the wheel, measure the chain slack again at the tightest position, and readjust if necessary.
  • Page 23: Front Fork

    PREPARATION 21 WARNING If both spring preload adjusters and both rebound and compression damp- ing adjusters are not adjusted equally, handling may be impaired and a haz- ardous condition may result. Set all suspension adjusters equally to the rec- ommended settings. Rebound Damping Adjustment •...
  • Page 24: Rear Shock Absorber

    22 PREPARATION Rear Shock Absorber Rebound Damping Adjustment • Check the position of the rebound damping adjuster at the lower end of the rear shock absorber. STD Rebound Damping: 1 1/2 turns out (Counterclockwise from the fully seated position) A. Tire Air Pressure Gauge Fuel WARNING Gasoline is extremely flammable and...
  • Page 25: Engine Oil (4-stroke)

    PREPARATION 23 Engine Oil (4-stroke) Engine Oil Level Inspection NOTE ○ This vehicle’s engine is filled with 10W-40 oil from the factory. DO NOT DRAIN and refill the crankcase before use. Check oil level and drain plug tightness. Engine Oil Drain Plug Torque: 29 N·m (3.0 kgf·m, 21 ft·lb) A.
  • Page 26: Throttle Grip And Cable

    24 PREPARATION Throttle Grip and Cable Throttle Grip Free Play Inspection • Inspect the throttle grip free play. If the free play is incorrect, adjust the throttle cables. Throttle Grip Free Play: 2 ∼ 3 mm (0.08 ∼ 0.12 in.) •...
  • Page 27: Idle Speed Adjustment

    PREPARATION 25 Idle Speed Adjustment • Start the engine and warm it up thoroughly. • Adjust the idle speed to 1 050 ∼ 1 150 r/min (rpm) by turning the idle adjusting screw. Idle Speed: 1 050 ∼ 1 150 r/min (rpm) A.
  • Page 28 26 PREPARATION A. mph·km/h Display B. °F /°C Display • The mph·km/h (and °F/°C temperature) dis- play shifts as follows. NOTE ○ The data is maintained even if the battery is disconnected.
  • Page 29 PREPARATION 27 This page intentionally left blank.
  • Page 30: Fastener Check

    28 PREPARATION Fastener Check • The torque values listed are for assembly and preparation items only, see the appropriate Service Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before retail delivery. Also check to see that each cotter pin or circlip is in place.
  • Page 31 PREPARATION 29 Torque Fastener Remarks N·m kgf·m ft·lb Steering Handlebar clamp bolt Brake Front master cylinder bleed valve 0.80 69 in·lb Front master cylinder clamp bolt 97 in·lb Front caliper bleed valve (Left and Right) 0.80 69 in·lb Front caliper mounting bolt (Left and Right) Rear caliper bleed valve 0.80 69 in·lb...
  • Page 32: Standard Torque Table

    30 PREPARATION Electrical System: Standard Torque Table Headlight - check high and low beams. This table relating tightening torque to thread Taillight - check operation. diameter, lists the basic torque for bolts and Brake Light - check operation. nuts. Use this table for only the bolts and nuts Turn Signal Lights - check operation.
  • Page 34 MODEL APPLICATION Year Model Name 2011 ZR750NBF Z750R 2011 ZR750PBF Z750R ABS Part No. 99939-1333-01...

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