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Kawasaki GPz750 Turbo
Technical Training
The following is Part 1 of the Kawasaki GPz 750 Turbo Technical Training Manual.
It deals with turbocharger system theory and operation. Kawasaki used this manual to help
train their personnel to understand and troubleshoot the turbo monster. Though some of it
has the unmistakable sound of corporate chest-beating (but hey, why not?) there's a lot of
good science contained in these pages for owners and tinkerers of any turbo persuasion.
Part II with feature a turbocharger troubleshooting guide. Look for it in our winter edi-
tion. Thanks to Jill A. Dunning of Kawasaki's Consumer Services Dept. for supplying the
TMIOA with this manual.
What makes Kawasaki's 750 Turbo the world's fastest? Learn just how easy it is to
understand, troubleshoot, and tune this high technology system.
This is a comprehensive, technically-oriented program that focuses on systems and
components unique to the 750 Turbo.
Major emphasis is placed on theory and maintenance of the turbocharger system,
while other topics covered include suspension, chassis, internal engine and Digital
Fuel Injection components.
Upon review of the 750 Turbo Course, the student will:
• Thoroughly understand the turbocharger and all related systems (such as wastegate
valve and actuator, boost pressure sensor and LCD boost indicator).
• Have awareness of the other differences between the GPz750 and the 750 Turbo.
All rights reserved. No part of this publication may be reproduced, stored in a retrieval sys-
tem, or transmitted in any form or by any means, electronic mechanical photocopying,
recording or otherwise, without the prior written permission of Technical Services,
Kawasaki Motors Corp., U.S.A. No liability can be accepted for any inaccuracies or omis-
sions in this publication, although every possible care has been taken to make it as complete
and accurate as possible. All procedures and specifications subject to change without prior
notice or obligation. Illustrations in this publication are intended for reference use only and
may not depict actual model component parts.
TURBO MOTORCYCLE INTERNATIONAL OWNERS ASSOCIATION • FALL 1996
Manual
INTRODUCTION
©1984 Kawasaki Motors Corp., U.S.A.
15

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Table of Contents

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   Summary of Contents for Kawasaki GPz750 Turbo

  • Page 1 Thanks to Jill A. Dunning of Kawasaki’s Consumer Services Dept. for supplying the TMIOA with this manual. INTRODUCTION What makes Kawasaki’s 750 Turbo the world’s fastest? Learn just how easy it is to understand, troubleshoot, and tune this high technology system. This is a comprehensive, technically-oriented program that focuses on systems and components unique to the 750 Turbo.
  • Page 2: Table Of Contents

    Turbocharger System Theory and Operation TURBOCHARGER FEATURES ....................17 TURBOCHARGER COMPONENTS ..................17 DFI SYSTEM COMPONENTS AND OPERATION ...............19 LUBRICATION SYSTEM ......................24 CHANGES IN THE 750 TURBO FROM THE GPz 750 ............25 TURBO MOTORCYCLE INTERNATIONAL OWNERS ASSOCIATION • FALL 1996...
  • Page 3: Turbocharger Features

    System are made as short as possible by Manual for service information. placing the turbocharger low and in front of the engine and the air cleaner near the engine sprocket. As a result, Kawasaki’s Turbocharger System offers these extra TURBOCHARGER FEATURES advantages: •...
  • Page 4 as the wheel turns. The housing shape allows the speed of the air to drop as it comes off the compressor wheel blades. The drop in speed increases the air pres- sure as the air flows toward the engine. A special casting method has been used to shape the compressor wheel blades.
  • Page 5: Dfi System Components And Operation

    DFI SYSTEM COMPONENTS AND OPERATION Kawasaki’s DFI (Digital Fuel Injection) system used on the 750 Turbo is based upon that of the GPz1100. The DFI system computes the optimum fuel injection quantity according to the...
  • Page 6 1. Turbocharger 7. Fuel Filter 13. Throttle Sensor 2. Compressor 8. Fuel Pump 14. Boost Pressure Sensor 3. Turbine 9. Injector 15. Air Temperature Sensor 4. Centerhousing 10. Air Cleaner 16. Engine Temperature Sensor 5. Boost Control 11. Surge Tank 17.
  • Page 7 TURBO MOTORCYCLE INTERNATIONAL OWNERS ASSOCIATION • FALL 1996...
  • Page 8 fuel quantity at idle. INJECTOR TIMING During cold starting only, the 360 degree injec- tion cycle is used. Injection timing is changed in Injection timing is changed accordance with cylinder head temperature as from a 360 degree injection shown below. cycle (1 injection/1 crankshaft rotation ) to a 720 degree injec- Injection Timing...
  • Page 9 tem, the fuel quantity is not enriched until Boost pressure is controlled at the tur- the next closest normal injection point. bocharger with the wastegate and its actuator. As a further safety measure, the DFI system cuts off fuel supply to the NOTE : engine by interrupting the injector signal if the boost pressure exceeds the preset...
  • Page 10: Lubrication System

    This graph shows that for any given fuel have plagued other turbocharger systems. flow rate (combined injector flow), a far The turbo shaft bearings are lubricated by greater pressure is possible. This is nec- oil directly from the oil cooler. That oil is essary because of the greater injectors then “pulled”...
  • Page 11: Changes In The 750 Turbo From The Gpz 750

    750cc engine and still maintain a high degree of relia- bility, acceptable off-boost performance and good high-speed handling, Kawasaki made several changes to the base model GPz750 engine, drive train and chassis. The following to a list of the most signifi- cant changes.
  • Page 12 been changed as shown to provide less travel has been reduced from 6.2 to 5.1 maximum spark advance and thus further inches. reduce the possibility of detonation. Rear Suspension TRANSMISSION The shock absorber has heavier damp- ing, a stronger constant rate spring, and Different primary gear ratios (larger shock travel is reduced.
  • Page 13 The aluminum swing arm wall thickness For better high speed stability, the has been increased by 0.5 mm to add frame geometry has been changed as rigidity. shown below. FRAME 750 Turbo GPz750 Rake Angle 28 deg 26.5 deg The steering head pipe has been length- Trail 117 mm 103 mm...

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