Kawasaki NINJA ZX-7R - SERVICE Manuals

Manuals and User Guides for KAWASAKI NINJA ZX-7R - SERVICE. We have 3 KAWASAKI NINJA ZX-7R - SERVICE manuals available for free PDF download: Service Manual, Owner's Manual

KAWASAKI NINJA ZX-7R - SERVICE Service Manual (364 pages)

Brand: KAWASAKI | Category: Motorcycle | Size: 45.36 MB

List Of Abbreviations 2

Quick Reference Guide 3

Emission Control Information 5

General Information 9

Before Servicing 10

Model Identification 12

ZX750-N1 Left Side View 12

ZX750-N1 Right Side View 12

ZX750-N1 (Europe Model) Left Side View 13

ZX750-N1 (Europe Model) Right Side View 13

ZX750-P1 (US And Canada Models) Left Side View 14

ZX750-P1 (US And Canada Models) Right Side View 14

ZX750-P1 (Europe Model) Left Side View 15

ZX750-P1 (Europe Model) Right Side View 15

General Specifications 16

Periodic Maintenance Chart 20

Technical Information - Maintenance Free Battery 21

Filling The Battery With Electrolyte 22

Initial Charge 23

Battery Precautions 24

Interchangeability With Ordinary Battery 24

Throttle Mechanism 25

Accelerator Pumps 25

Technical Information - Flat CR Slide Carburetor 25

Fuel Enricher 26

Technical Information - Side Camshaft Chain 27

Technical Information - Engine Lubrication System 28

Technical Information - Connecting Rod Big End Nut Tightening 29

Technical Information - Swingarm 32

Technical Information - Alternator Unit 32

Torque And Locking Agent 33

Special Tools And Sealant 38

Cable, Wire And Hose Routing 44

Evaporative Emission Control System (California) 54

Fuel System 57

Fuel System Exploded View 58

Fuel System Specifications 64

Throttle Grip And Cables 66

Free Play Inspection 66

Free Play Adjustment 66

Cable Installation 66

Cable Lubrication 67

Choke Cable Free Play Inspection 68

Choke Cable Free Play Adjustment 68

Choke Cable Installation 68

Choke Cable Lubrication 68

Carburetors Idle Speed Inspection 69

Carburetors Idle Speed Adjustment 69

Carburetors Synchronization Inspection 69

Carburetors Synchronization Adjustment 70

Carburetors Service Fuel Level Inspection 72

Carburetors Service Fuel Level Adjustment 72

Carburetors Fuel System Cleanliness Inspection 73

Carburetor Removal 73

Carburetor Installation 74

Carburetor Disassembly/Assembly 74

Carburetor Separation/Assembly 75

Carburetor Cleaning 75

Carburetor Inspection 76

High Altitude Performance Adjustment (US Model) 77

Coolant Filter Cleaning (AR, FG, FR, IT, KR, NL, ST, UK) 77

Air Cleaner Housing Removal 78

Air Cleaner Housing Installation 78

Air Cleaner Element Removal 78

Air Cleaner Element Installation 79

Air Cleaner Element Cleaning And Inspection 79

Air Cleaner Oil Draining 79

Fuel Tank Removal 80

Fuel Tank Installation 80

Fuel Tank Inspection 80

Fuel Tank Cleaning 81

Fuel Tap Removal 81

Fuel Tap Installation 81

Fuel Tap Inspection 82

Fuel Pump Removal 83

Fuel Filter Removal 83

Fuel Filter Installation 84

Fuel Pump Inspection 84

Fuel Filter Inspection 84

Vacuum Valve Inspection 85

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 86

Evaporative Emission Control System Canister Inspection 87

Cooling System 89

Cooling System Exploded View 90

Coolant Flow Chart 91

Cooling System Specifications 92

Coolant Level Inspection 93

Coolant Draining 93

Coolant Filling 94

Pressure Testing 95

Water Pump Removal 96

Water Pump Installation 96

Water Pump Inspection 96

Radiator, Radiator Fan Removal 97

Radiator Inspection 98

Radiator Cap Inspection 98

Thermostat Removal 100

Thermostat Installation 100

Thermostat Inspection 100

Radiator Fan Switch, Water Temperature Sensor Removal 102

Radiator Fan Switch, Water Temperature Sensor Installation 102

Radiator Fan Switch, Water Temperature Sensor Inspection 102

Engine Top End 103

Engine Top End Exploded View 104

Engine Top End Specifications 106

Clean Air System 108

Air Suction Valve Inspection 108

Vacuum Switch Valve Removal 108

Vacuum Switch Valve Installation 108

Clean Air System Hose Inspection 109

Cylinder Head Cover Removal 110

Cylinder Head Cover Installation 110

Camshaft Chain Tensioner Removal 112

Camshaft Chain Tensioner Installation 112

Camshaft Removal 113

Camshaft Installation 113

Camshaft, Camshaft Cap Wear 115

Camshaft Chain Removal 115

Camshaft Chain Wear 115

Cylinder Compression Measurement 116

Cylinder Head Removal 116

Cylinder Head Installation 117

Valve Clearance Inspection 119

Valve Clearance Adjustment 119

Valve Clearance Adjustment Chart 120

Valve Removal 122

Valve Installation 122

Valve Guide Removal 122

Valve Guide Installation 122

Valve Seat Inspection 123

Valve Seat Repair 123

Seat Cutter Operation Care 124

Marks Stamped On The Cutter 124

Cylinder Removal 127

Cylinder Installation 127

Piston Removal 127

Piston Installation 128

Cylinder Wear 128

Piston Wear 129

Piston Ring, Piston Ring Groove Wear 129

Piston Ring End Gap 129

Carburetor Holder Installation 130

Muffler Removal 131

Muffler Installation 131

Clutch 133

Clutch Exploded View 134

Clutch Specifications 135

Clutch Fluid Level Inspection 136

Clutch Fluid Change 136

Bleeding The Clutch Line 137

Clutch Master Cylinder Removal 138

Clutch Master Cylinder Installation 138

Clutch Master Cylinder Disassembly 138

Clutch Master Cylinder Assembly 139

Clutch Master Cylinder Inspection (Visual Inspection) 139

Clutch Slave Cylinder Removal 140

Clutch Slave Cylinder Installation 140

Clutch Slave Cylinder Disassembly 140

Clutch Slave Cylinder Assembly 141

Clutch Removal 142

Clutch Installation 142

Spring Plate Free Play Measurement 145

Spring Plate Free Play Adjustment 146

Clutch Plate, Wear, Damage Inspection 147

Clutch Plate Warp Inspection 147

Clutch Spring Free Length Measurement 147

Damper Cam Inspection 147

Engine Lubrication System 149

Engine Lubrication System Exploded View 150

Engine Oil Flow Chart 151

Engine Lubrication System Specifications 152

Engine Oil Level Inspection 153

Engine Oil Change 153

Engine Oil Filter Change 154

Oil Cooler Removal 155

Oil Cooler Installation 155

Oil Pan Removal 156

Oil Pan Installation 156

Oil Pump Removal 157

Oil Pump Installation 157

Oil Pressure Measurement 158

Relief Valve Inspection 159

Engine Removal/Installation 161

Engine Removal/Installation Exploded View 162

Engine Removal/Installation Specifications 163

Engine Removal 164

Engine Installation 165

Crankshaft/Transmission 167

Crankshaft/Transmission Exploded View 168

Crankshaft/Transmission Specifications 170

Crankcase Splitting 172

Crankcase Assembly 172

Crankshaft Removal 174

Crankshaft Installation 174

Connecting Rod Removal 174

Connecting Rod Installation 174

Connecting Rod Big End Bearing Insert/Crankpin Wear 177

Crankshaft Main Bearing Insert/Journal Wear 178

Crankshaft Side Clearance 180

Alternator Chain Adjustment 181

Alternator Chain Removal 181

Alternator Chain Installation 182

Alternator Shaft, Starter Clutch Removal 182

Alternator Shaft, Starter Clutch Installation 183

Starter Clutch Disassembly 183

Starter Clutch Assembly 183

ALternator Shaft Chain Wear 183

Chain Guide Wear 184

Starter Clutch Inspection 184

Starter Motor Idle Gear Removal 185

Starter Motor Idle Gear Installation 185

Transmission 186

Shift Pedal Removal 186

Shift Pedal Installation 186

External Shift Mechanism Removal 186

External Shift Mechanism Installation 187

External Shift Mechanism Assembly 187

Transmission Shaft Removal 188

Transmission Shaft Installation 188

Transmission Disassembly 188

Transmission Assembly 188

Shift Drum And Fork Removal 189

Shift Drum And Fork Installation 189

Shift Drum Disassembly 190

Shift Drum Assembly 190

Drive Shaft 191

Output Shaft 191

Wheels/Tires 193

Wheels/Tires Exploded View 194

Wheels/Tires Specifications 195

Additional Standard Tires (ZX750P) 196

Front Wheel Removal 198

Rear Wheel Removal 199

Rear Wheel Installation 199

Wheel Inspection 200

Axle Inspection 200

Balance Inspection 200

Balance Adjustment 201

Balance Weight Removal 201

Balance Weight Installation 201

Air Pressure Inspection/Adjustment 203

Tire Inspection 203

Tire Removal 204

Tire Installation 204

Repair 206

Hub Bearing Removal 207

Hub Bearing Installation 207

Hub Bearing Inspection 207

Speedometer Gear Housing Disassembly And Assembly 208

Speedometer Gear Housing Lubrication 208

Final Drive 209

Final Drive Exploded View 210

Final Drive Specifications 211

Drive Chain Slack Inspection 212

Drive Chain Slack Adjustment 212

Wheel Alignment Inspection/Adjustment 212

Drive Chain Wear Inspection 213

Drive Chain Lubrication 213

Drive Chain Removal 214

Drive Chain Installation 214

Chain Guard Removal 215

Chain Guard Installation 215

Engine Sprocket Removal 216

Engine Sprocket Installation 216

Rear Sprocket Removal 217

Rear Sprocket Installation 217

Sprocket Wear Inspection 217

Rear Sprocket Warp Inspection 217

Coupling Bearing Removal 218

Coupling Bearing Installation 218

Coupling Bearing Inspection And Lubrication 218

Brakes 221

Brakes Exploded View 222

Brakes Specifications 224

Brake Pedal Position Inspection 225

Brake Pedal Position Adjustment 225

Caliper Removal 226

Caliper Installation 226

Front Caliper Disassembly 226

Rear Caliper Disassembly 227

Caliper Assembly 228

Front Brake Pad Removal 229

Front Brake Pad Installation 229

Rear Brake Pad Removal 231

Rear Brake Pad Installation 231

Lining Wear 231

Front Master Cylinder Removal 232

Front Master Cylinder Installation 232

Rear Master Cylinder Removal 232

Rear Master Cylinder Installation 233

Front Master Cylinder Disassembly 233

Rear Master Cylinder Disassembly 233

Master Cylinder Assembly 234

Master Cylinder Inspection (Visual Inspection) 234

Brake Disc Removal 235

Brake Disc Installation 235

Brake Disc Wear 235

Brake Disc Warp 235

Brake Fluid Level Inspection 236

Brake Fluid Change 236

Bleeding The Brake Line 237

Brake Hose Removal/Installation 239

Brake Hose Inspection 239

Suspension 241

Suspension Exploded View 242

Suspension Specifications 245

Front Fork 246

Rebound Damping Force Adjustment 246

Compression Damping Force Adjustment 246

Spring Preload Adjustment 247

Front Fork Removal (each Fork Leg) 247

Front Fork Installation 248

Fork Oil Change (ZX750N) 248

Fork Oil Change (ZX850P) 251

Front Fork Disassembly (ZX750N) 253

Front Fork Assembly (ZX750N) 254

Front Fork Disassembly (ZX750P) 255

Front Fork Assembly (ZX750P) 256

Inner Tube Inspection 257

Dust Seal Inspection 257

Spring Tension 257

Rear Shock Absorber 258

Remound Damping Fork Adjustment (ZX750N) 258

Rebound Damping Force Adjustment (ZX750P) 258

Rear Shock Absorber Removal 259

Rear Shock Absorber Installation 260

Rear Shock Absorber Scrapping 260

Swingarm Removal 261

Swingarm Installation 262

Swingarm Bearing Removal 262

Swingarm Bearing Installation 262

Tie-Rod Removal 263

Tie-Rod Installation 263

Rocker Arm Removal 263

Rocker Arm Installation 263

Needle Bearing Inspection 264

Tie-Rod, Rocker Arm Sleeve Inspection 264

Steering 265

Steering Exploded View 266

Steering Specifications 267

Steering Inspection 268

Steering Adjustment 268

Stem, Stem Bearing Removal 269

Stem, Stem Bearing Installation 269

Stem Bearing Lubrication 271

Handlebar Removal 272

Handlebar Installation 272

Frame 273

Frame Exploded View 274

Seat Removal (ZX750N) 277

Seat Installation (ZX750N) 277

Rear Seat Removal (ZX750P) 277

Rear Seat Installation (ZX750P) 277

Front Seat Removal (ZX750P) 278

Front Seat Installation (ZX750P) 278

Seat Cover Removal 279

Side Cover Removal 280

Side Cover Installation 280

Inner Fairing Removal 281

Inner Fairing Installation 281

Upper Fairing Removal 281

Lower Fairing Removal 281

Front Fender Removal 282

Rear Fender Removal 282

Rear Fender Installation 282

Battery Case Removal 283

Rear Frame Removal 284

Rear Frame Installation 284

Electrical System 285

Electrical System Exploded View 286

Electrical System Specifications 289

Electrical System Parts Location 290

Electrical System Precautions 291

Electrical Wiring Inspection 292

Battery Charging Condition Inspection 293

Battery Refreshing Charge 293

Battery Standard Charge Time Chart 294

Alternator Removal 295

Alternator Installation 295

Alternator Disassembly 295

Alternator Assembly 297

Operational Inspection 299

Stator Coil Inspection 300

Rotor Coil Inspection 300

Slip Ring Cleaning 300

Slip Ring Diameter 301

Carbon Brush Length 301

Rectifier Inspection 301

Regulator Inspection 301

Alternator Ball Bearing Inspection 302

Alternator Circuit 303

Ignition System 304

Pickup Coil Removal 304

Pickup Coil Installation 304

Pickup Coil Inspection 305

Ignition Coil Removal 305

Ignition Coil Installation 305

Ignition Coil Inspection 306

Spark Plug Removal 306

Spark Plug Installation 307

Spark Plug Gap Inspection 307

IC Igniter Inspection 307

IC Igniter Troubleshooting 310

Ignition System Circuit 311

Starter Motor Removal 312

Starter Motor Installation 312

Starter Motor Disassembly 313

Starter Motor Assembly 313

Brush Inspection 314

Commutator Cleaning And Inspection 314

Armature Inspection 315

Brush Lead Inspection 315

Brush Plate And Terminal Bolt Inspection 315

Starter Relay Inspection 315

Electric Starter Circuit 316

Lighting System 317

Headlight Beam Horizontal Adjustment 317

Headlight Beam Vertical Adjustment 317

Headlight Bulb Replacement 317

Headlight Diode Inspection 318

Headlight Circuit 319

Turn Signal Relay Inspection 321

Turn Signal Light Circuit 322

Fuel Pump Removal/Installation 323

Fuel Pump Relay Inspection 323

Fuel Pump Operational Inspection 323

Fuel Pump Relay Internal Resistance 323

Fuel Pump Pressure 324

Fuel Pump Circuit 324

Radiator Fan System 325

Fan System Circuit Inspection 325

Fan Motor Inspection 325

Radiator Fan Circuit 325

Meter, Gauge Removal 326

Meter, Gauge Disassembly 326

Meter, Gauge Bulb Replacement 326

Tachometer Inspection 326

Tachometer Circuit 327

Water Temperature Gauge Inspection 328

Gauge Operation Test 328

Water Temperature Gauge Circuit 328

Switches And Sensors 329

Brake Light Timing Inspection 329

Brake Light Timing Adjustment 329

Switch Inspection 329

Radiator Fan Switch Inspection 330

Water Temperature Sensor Inspection 330

Throttle Switch Inspection (ZX750N) 330

Fuel Enricher Solenoid Valve Inspection 332

Fuel Enricher Solenoid Valve Circuit 332

Junction Box Fuse Circuit Inspection 333

Starter Circuit/Headlight Relay Inspection 333

Diode Circuit Inspection 334

Junction Box Internal Circuit 335

30A Main Fuse Removal 336

Junction Box Fuse Removal 336

Fuse Installation 336

Fuse Inspection 336

ZX750N Wiring Diagram 338

ZX750P Wiring Diagram 344

Appendix 353

Additional Consideration For Racing 354

Troubleshooting Guide 356

Engine Doesn't Start, Starting Difficulty 356

Poor Running At Low Speed 356

Poor Running Or No Power At High Speed 357

Overheating 357

Over Cooling 357

Clutch Operation Faulty 357

Gear Shifting Faulty 358

Abnormal Engine Noise 358

Abnormal Drive Train Noise 358

Abnormal Frame Noise 358

Exhaust Smoke Excessively 359

Handling And/or Stability Unsatisfactory 359

Brake Doesn't Hold 359

Battery Trouble 359

General Lubrication 360

Nuts, Bolt And Fastener Tightness 361

Tightness Inspection 361

Unit Conversion Table 362

Kawasaki NINJA ZX-7R - SERVICE Service Manual (363 pages)

Brand: Kawasaki | Category: Motorcycle | Size: 45.5 MB

(Norwegian) KAWASAKI NINJA ZX-7R - SERVICE Owner's Manual (53 pages)

Brand: KAWASAKI | Category: Motorcycle | Size: 3.62 MB

Table Of Contents 5

Specifications 6

Location Of Parts 7

General Information 9

Meter Instruments 9

Speedometer And Tachometer 9

Indicator Lights 9

Key 10

Ignition Switch/Steering Lock 10

Right Handlebar Switches 11

Engine Stop Switch 11

Starter Button 11

Headlight Switch 11

Left Handlebar Switches 12

Dimmer Switch 12

Turn Signal Switch 12

Horn Button 12

Fuel Tank 13

Fuel Requirement 13

Octane Rating 13

Fuel Tap 14

Side Stand 14

Seats 15

Helmet Hook 16

Tool Kit 16

Tying Hooks 16

Break-In 17

How To Ride The Motorcycle 17

Starting The Engine 17

Jump Starting 19

Moving Off 20

Shifting Gears 20

Braking 21

Stopping The Engine 21

Front Brake Lever 21

Rear Brake Lever 21

Stopping The Motorcycle In An Emergency 22

Parking 22

Safe Operation 23

Daily Safety Checks 23

Maintenance And Adjustment 24

Additional Considerations For High Speed Operation 24

Periodic Maintenance Chart 25

Engine Oil 26

Oil Level Inspection 26

Oil And/or Oil Filter Change 27

Cooling System 28

Radiator And Cooling Fan 28

Tightening Torque 28

Engine Oil Specifications 28

Radiator Hoses 29

Coolant 29

Coolant Level Inspection 30

Coolant Change 30

Spark Plugs Removal 31

Spark Plug Maintenance 31

Valve Clearance 32

Air Cleaner 32

Element Removal 32

Spark Plug Specifications 32

Element Cleaning 33

Throttle Grip Inspection 34

Throttle Grip Adjustment 34

Choke Lever Inspection 35

Choke Lever Adjustment 35

Carburetors Adjustment 36

Idle Adjusting Screw 36

Clutch Inspection 37

Clutch Adjustment 37

Drive Chain 38

Chain Slack Inspection 38

Drive Chain Slack 38

Chain Slack Adjustment 38

Drive Chain Wear Inspection 39

Drive Chain Lubrication 40

Brake Wear Inspection 41

Brake Camshaft Lubrication 41

Disc Brake Fluid 41

Fluid Requirement 41

Front Brake 42

Rear Brake 42

Fluid Level Inspection 42

Pedal Position Inspection 42

Brake Light Switches 43

Pedal Position Adjustment 43

Pedal Play Inspection 43

Pedal Play Adjustment 43

Rear Shock Absorbers 44

Spring Adjustment 44

Wheels 45

TUBELESS Mark 45

Tires: Payload And Tire Pressure 45

Tire Air Pressure 46

Tire Wear, Damage 46

Minimum Tread Depth 46

Tire Pressure/Depth Gauge 46

Battery Electrolyte Level Inspection 47

Standard Tire 47

Headlight Beam Horizontal Adjustment 48

Battery Removal 48

Battery Installation 48

Fuses 49

Headlight Beam Vertical Adjustment 49

Fuel System Inspection 50

Cleaning 51

Preparation For Washing 51

After Washing 51

Preparation For Storage 52

Preparation After Storage 53

KAWASAKI Categories

Motorcycle Engine Offroad Vehicle Utility Vehicle Boat

More KAWASAKI Manuals...

Kawasaki NINJA ZX-7R - SERVICE Manuals

Manuals and User Guides for KAWASAKI NINJA ZX-7R - SERVICE. We have 3 KAWASAKI NINJA ZX-7R - SERVICE manuals available for free PDF download: Service Manual, Owner's Manual

KAWASAKI NINJA ZX-7R - SERVICE Service Manual (364 pages)

Table of contents

Kawasaki NINJA ZX-7R - SERVICE Service Manual (363 pages)

(Norwegian) KAWASAKI NINJA ZX-7R - SERVICE Owner's Manual (53 pages)

Table of contents

Related Products

KAWASAKI Categories

Kawasaki NINJA ZX-7R - SERVICE Manuals

Manuals and User Guides for KAWASAKI NINJA ZX-7R - SERVICE. We have 3 KAWASAKI NINJA ZX-7R - SERVICE manuals available for free PDF download: Service Manual, Owner's Manual

KAWASAKI NINJA ZX-7R - SERVICE Service Manual (364 pages)

Table of contents

Kawasaki NINJA ZX-7R - SERVICE Service Manual (363 pages)

(Norwegian) KAWASAKI NINJA ZX-7R - SERVICE Owner's Manual (53 pages)

Table of contents

Share and save

Related Products

KAWASAKI Categories