User manual KAWASAKI Z750

[. . . ] Z750 Z750 ABS Motorcycle Service Manual Quick Reference Guide General Information Periodic Maintenance Fuel System (DFI) Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal/Installation Crankshaft/Transmission Wheels/Tires Final Drive Brakes Suspension Steering Frame Electrical System This quick reference guide will assist you in locating a desired topic or procedure. ·Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. ·Refer to the sectional table of contents for the exact pages to locate the specific topic required. 1j 2j 3j 4j 5j 6j 7j 8j 9j 10 j 11 j 12 j 13 j 14 j 15 j 16 j Appendix 17 j Z750 Z750 ABS Motorcycle Service Manual All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Quality Assurance Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd. , Japan. [. . . ] · Start the engine at the specified speed, and read the oil Run · pressure gauge. If the oil pressure is much lower than the standard, check the oil pump, relief valve, and/or crankshaft bearing insert wear immediately. If the reading is much higher than the standard, check the oil passages for clogging. Oil Pressure Standard: 147 226 kPa (1. 5 2. 3 kgf/cm², 21 33 psi) at 4 000 r/min (rpm), oil temperature 90°C (194°F) engine. Remove · WARNING Take care against burns form hot engine oil that will drain through the oil passage when the gauge adapter is removed. locking agent to the oil passage plug, Torque - Oil Passage Plugs: 20 N·m (2. 0 kgf·m, 15 ft·lb) ENGINE LUBRICATION SYSTEM 7-13 Oil Pressure Switch Oil Pressure Switch Removal Maintenance chapter) Switch Cover [A] Switch Terminal Bolt [B] Oil Pressure Switch [C] · Remove:Oil (Drain, see Engine Oil Change in the Periodic Engine Oil Pressure Switch Installation · Apply silicone sealant to the threads of the oil pressure switch and tighten it. Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 the switch lead direction · Install high-temperature grease upward. · Torque - Oil Pressure Switch: 15 N·m (1. 5 kgf·m, 11 ft·lb) Torque - Oil Pressure Switch Terminal Bolt: 2. 0 N·m (0. 20 kgf·m, 18 in·lb) ENGINE REMOVAL/INSTALLATION 8-1 Engine Removal/Installation Table of Contents Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Special Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-4 8-5 8-5 8-7 8 8-2 ENGINE REMOVAL/INSTALLATION Exploded View ENGINE REMOVAL/INSTALLATION 8-3 Exploded View No. 1 2 3 4 5 6 7 8 9 Fastener Adjusting Collar Lock Bolt Adjusting Collar Locknut Engine Ground Cable Terminal Bolt Front Engine Mounting Bolts Lower Engine Mounting Nut Middle Engine Mounting Nut Rear Engine Bracket Bolts Subframe Bolts Upper Engine Bracket Bolts N·m 34 49 9. 8 44 44 44 25 25 44 Torque kgf·m 3. 5 5. 0 1. 0 4. 5 4. 5 4. 5 2. 5 2. 5 4. 5 ft·lb 25 36 87 in·lb 32 32 32 18 18 32 Remarks S S S S S S S S S: Follow the specified tightening sequence. 8-4 ENGINE REMOVAL/INSTALLATION Special Tool Engine Mount Nut Wrench: 57001-1450 ENGINE REMOVAL/INSTALLATION 8-5 Engine Removal/Installation Engine Removal of the swingarm with a stand. · Support the rear partlever slowly and hold it with a band Squeeze the brake · [A]. WARNING Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. It could cause an accident and injury. CAUTION Be sure to hold the front brake when removing the engine, or the motorcycle may fall over. The engine or the motorcycle could be damaged. · Remove:Oil (Drain, see Engine Oil Change in the Periodic Engine Maintenance chapter) Coolant (Drain, see Coolant Change in the Periodic Maintenance chapter) Center Fairings (see Center Fairing Removal in the Frame chapter) Side Covers (see Side Cover Removal in the Frame chapter) Frame Covers (see Frame Cover Removal in the Frame chapter) Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) Clutch Cable Lower End (see Clutch Cable Removal in the Clutch chapter) Thermostat Housing (see Thermostat Removal in the Cooling System chapter) Radiator (see Radiator and Radiator Fan Removal in the Cooling System chapter) Air Switching Valve (see Air Switching Valve Removal in the Engine Top End chapter) Throttle Body Assy (see Throttle Body Assy Removal in the Fuel System (DFI) chapter) Shift Lever (see Shift Pedal Removal in the Crankshaft/Transmission chapter) · Remove: [A] Quick Rivets Exhaust Pipe (see Exhaust Pipe Removal in the Engine Top End chapter) 8-6 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation · Disconnect:Harness Connector [A] Stick Coil Camshaft Position Sensor Lead Connector (see Camshaft Position Sensor Removal in the Electrical System chapter) · Disconnect: Cable (see Starter Motor Removal in the Starter Motor Electrical System chapter) Alternator Lead Connector (see Alternator Cover Removal in the Electrical System chapter) Crankshaft Sensor Lead Connector (see Crankshaft Sensor Removal in the Electrical System chapter) Neutral Switch Lead Connector [A] Sidestand Switch Lead Connector [B] Speed Sensor Lead Connector [C] Remove the engine sprocket (see Engine Sprocket Removal in the Final Drive chapter). · · Remove: Hose End [A] Breather Engine Ground Cable Terminal Bolt [B] engine with a suitable stand [A]. Put a plank · Remove: Mounting Bolts [A] (Both Sides) Front Engine Adjusting Collar Lock Bolt Subframe Bolts [B] (Both Sides) Upper Engine Bracket Bolts [C] (Both Sides) Subframes [D] (Both Sides) Middle Engine Mounting Nut [E] and Bolt Lower Engine Mounting Nut [F] and Bolt Rear Engine Bracket Bolts [G] Rear Engine Bracket [H] ENGINE REMOVAL/INSTALLATION 8-7 Engine Removal/Installation · Using the nut wrench [A], loosen the locknut [B]. Special Tool - Engine Mount Nut Wrench: 57001-1450 · Using the Hexagon Wrench, turn the adjusting collar [A] counterclockwise to make the gap between the engine and adjusting collar. chain · Remove the drivetake out[A] from the output shaft [B]. · Engine Installation engine · Support the onto thewith a suitable stand. Put a plank suitable stand for engine the adjusting collar [A] to the frame. Screw · 8-8 ENGINE REMOVAL/INSTALLATION Engine Removal/Installation engine · Install theinstallingmounting bolts and nuts, following the specified sequence. First, hang the drive chain over the output shaft just before Second, install the rear engine bracket [A] and tighten the Third, install the left upper engine bracket [C] and left subFourth, insert the lower [H] and middle [I] engine mounting frame [D] and tighten the bolts [E] [F] [G]. moving the engine into its final position in the frame. Fifth, tighten the left front engine mounting bolt [J]. Seventh, tighten the adjusting collar [K] until the clearEighth, tighten the adjusting collar locknut [L]. Ninth, tighten the lower [M] and middle [N] engine mountTenth, install the right upper engine bracket [O] and right ing nuts. [. . . ] Clamp (Hold the clutch cable and left switch housing lead from the backside of the chassis. ) 8. Band (Hold the main harness and clutch cable at inside of the front fork. Position the band at 20 mm (0. 79 in. ) from the end of PVC-sheet on the main harness. 17-40 APPENDIX Cable, Wire, and Hose Routing APPENDIX 17-41 Cable, Wire, and Hose Routing 1. Run the clutch cable and left switch housing lead inside the guide of the upper fairing bracket. [. . . ]