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Kawasaki Z750 2007 2008 2009 2010 Workshop Service Manual

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The Z750 (ZR750J, third generation) is a naked sportbike designed for riders seeking accessible performance and everyday usability. Produced from 2007 to 2010, this middleweight machine features an aggressive styling...
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Kawasaki Z750 2007 2008 2009 2010 Workshop Service ManualKawasaki Z750 2007 2008 2009 2010 Workshop Service ManualKawasaki Z750 2007 2008 2009 2010 Workshop Service ManualKawasaki Z750 2007 2008 2009 2010 Workshop Service Manual
The Z750 (ZR750J, third generation) is a naked sportbike designed for riders seeking accessible performance and everyday usability. Produced from 2007 to 2010, this middleweight machine features an aggressive styling philosophy, a potent liquid-cooled, 750 cc inline-four engine delivering approximately 104 hp, and a robust high-tensile steel backbone frame. Its engineering prioritizes a balance of sporty handling, a comfortable riding position, and practical versatility, making it suitable for commuting, spirited riding, and touring. Building on a rich heritage in the Z series, the Z750 offers a compelling package in its segment, often praised for its strong engine characteristics and value. This comprehensive Workshop Service Manual provides detailed guidance for the maintenance, repair, and troubleshooting of the Z750 (ZR750J) models from 2007 to 2010. Covering a vast array of systems, including engine mechanicals, fuel injection, cooling, exhaust, ignition, transmission, suspension, brakes, wheels, and electrical systems, this 677-page English-language manual is an essential resource. It offers in-depth procedures for routine maintenance, engine overhauls, fuel system service, suspension rebuilds, brake system repairs, and electrical diagnostics, complete with critical torque specifications and clearances. The manual is designed to assist owners, mechanics, and technicians in ensuring the optimal performance, reliability, and longevity of their Z750.
🏷️ Basic Information
Identification
Make:
Kawasaki
Model:
Z750
Generation
Generation Name:
ZR750J (Third Generation)
Codes
Chassis Code:
ZR750J
👋 Introduction
Market Position
Segment:
Naked sportbike, middleweight performance segment.
Competitive Analysis
Key Competitors:
Yamaha FZ6, Suzuki Bandit 650, Honda CB600F Hornet.
Key Features
Design Philosophy:
Aggressive styling, accessible performance, and practical everyday usability.
Target Audience:
Riders seeking a sporty yet versatile motorcycle for commuting, sport riding, and spirited touring.
📋 Manual Details
Coverage Areas
Model Years Covered:
2007, 2008, 2009, 2010
Page Count
Total Pages:
677
Manual Type
Type:
Workshop Service Manual
Language
Language:
English
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete engine teardown, assembly, inspection, and repair of all internal components (pistons, rings, cylinders, crankshaft, camshafts, valves, etc.).
Fuel System:
Fuel injection system (EFI), fuel pump, injectors, throttle body, fuel pressure regulator, fuel tank, lines, and evaporative emission control system.
Cooling System:
Radiator, coolant, water pump, thermostat, cooling fan, hoses, and related components.
Exhaust System:
Exhaust manifold, catalytic converter, muffler, and exhaust gaskets.
Ignition System:
Ignition coils, spark plugs, CDI unit, wiring, and troubleshooting.
Transmission Mechanical:
Clutch operation, gear selection mechanism, gear ratios, internal transmission components (gears, shafts, bearings), and maintenance.
Suspension Front:
Front fork assembly, internal components, oil types and capacities, seals, adjustments, and troubleshooting.
Suspension Rear:
Rear shock absorber, linkage system, swingarm, bearings, and adjustments.
Brakes Front:
Brake calipers, master cylinder, brake lines, brake pads, brake discs, and hydraulic system bleeding.
Brakes Rear:
Rear brake caliper, master cylinder, brake lines, brake pads, brake disc, and hydraulic system bleeding.
Wheels Tires:
Wheel bearing inspection, tire pressure, and wheel installation procedures.
Electrical System:
Battery, charging system (alternator/stator, rectifier/regulator), starting system (starter motor, solenoid), lighting system, and wiring diagrams.
Instrumentation:
Instrument cluster functions, speed sensor, tachometer, fuel gauge, and warning lights.
Lighting System:
Headlight, taillight, turn signals, brake light, and bulb replacement.
Bodywork Frame:
Fairings, seat, fuel tank removal/installation, frame inspection, and related components.
Steering:
Handlebar, steering stem, bearings, and front fork alignment.
Lubrication System:
Engine oil type, capacity, oil filter replacement, and oil pump.
Procedures Included
Routine Maintenance:
Oil and filter changes, spark plug replacement, air filter cleaning/replacement, chain adjustment, brake fluid replacement, coolant flush, and general inspection.
Troubleshooting:
Diagnostic procedures for common issues, error codes, electrical system faults, engine performance problems, and component failures.
Engine Overhaul:
Detailed steps for complete engine disassembly, inspection, measurement, component replacement, and reassembly.
Fuel Injection Service:
Cleaning and testing of fuel injectors, throttle body synchronization, and fuel pressure checks.
Suspension Rebuild:
Front fork seal replacement, oil level adjustments, and rear shock absorber service.
Brake System Repair:
Brake pad and disc replacement, caliper servicing, master cylinder overhaul, and hydraulic system bleeding.
Electrical Diagnostics:
Tracing wiring faults, testing electrical components, charging system checks, and starter system diagnostics.
Clutch Replacement:
Replacement of clutch plates and springs.
Tire Mounting:
Proper procedures for mounting and balancing tires on wheels.
Technical Depth
Depth Level:
Comprehensive (from basic maintenance to complete engine and transmission rebuilds).
Diagnostic Capability:
Detailed troubleshooting flowcharts and symptom-based diagnostics.
Torque Specifications:
All critical fastener torque specifications for engine, chassis, and suspension components.
Clearances Tolerances:
Precise measurement specifications for engine internal clearances and component tolerances.
Wiring Diagrams:
Detailed, color-coded electrical wiring diagrams for all systems.
📊 Manual Specifications
File Format
Format:
PDF
Print Quality
Quality:
High-resolution, optimized for digital viewing and printing.
Binding Type
Binding:
N/A (Digital PDF Download)
Paper Type
Paper:
N/A (Digital PDF Download)
Searchability
Text Search:
Likely searchable text within the PDF, allowing for quick information retrieval.
⚙️ Engine Specifications
Primary Engine
Engine Type:
Liquid-cooled, four-stroke, DOHC, inline-four cylinder
Displacement:
750 cc
Bore X Stroke:
68.4 mm x 50.9 mm
Compression Ratio:
11.5:1
Performance
Horsepower:
Approx. 104 hp @ 10,200 rpm (claimed)
Torque:
Approx. 75 Nm @ 9,500 rpm (claimed)
Fuel System
Fuel Delivery:
Electronic Fuel Injection (DFI) with sub-throttle valves
Fuel Type:
Unleaded premium gasoline
Lubrication
Oil Type:
API SG or SH, SAE 10W-40 recommended (verify manual for exact spec)
Oil Capacity:
3.4 L (with filter change) (verify manual for exact spec)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Optional
Optional Transmission:
N/A (No optional transmission offered for this model)
Features
Clutch Type:
Wet, multi-plate, manual
📐 Dimensions
Exterior
Overall Length:
Approx. 2,105 mm (82.9 in)
Overall Width:
Approx. 790 mm (31.1 in)
Overall Height:
Approx. 1,055 mm (41.5 in)
Wheelbase:
Approx. 1,440 mm (56.7 in)
Ground Clearance:
Approx. 150 mm (5.9 in)
Seat Height:
Approx. 815 mm (32.1 in)
Weights
Curb Weight:
Approx. 205 kg (452 lbs) (wet)
Fuel Tank Capacity:
15 Liters (3.96 US gal)
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Motorcycle safety ratings are not standardized like automotive; focus is on component performance and rider skill.)
Active Features
Braking System:
Dual 300mm petal discs with dual 2-piston calipers (front), Single 250mm petal disc with 2-piston caliper (rear). ABS was an optional feature on some markets.
Lighting:
Halogen headlight, LED taillight.
Passive Features
Frame Construction:
High-tensile steel backbone frame for rigidity and rider feedback.
💡 Technology Features
Infotainment
Infotainment System:
N/A (No integrated infotainment system on this model; focus is on functional instrumentation.)
Driver Assistance
ABS:
Anti-lock Braking System (ABS) was an optional feature available in some markets during these model years.
Connectivity
Connectivity Features:
N/A (No advanced connectivity features like Bluetooth or smartphone integration.)
Instrumentation
Dash Layout:
Digital speedometer, analog tachometer, fuel gauge, clock, trip meters, and various indicator lights.
🔧 Maintenance
Service Intervals
First Service:
Typically at 1,000 km (600 miles) or 1 month - includes oil change, filter inspection, chain adjustment, and general checks.
Major Service Interval:
Every 6,000 km (3,700 miles) or 6 months - includes valve clearance check, spark plug replacement, and thorough inspection of all systems.
Fluid Specifications
Engine Oil Spec:
API SG or SH, SAE 10W-40 (refer to manual for precise specification and alternatives).
Coolant Spec:
Mixture of permanent antifreeze and distilled water (50/50 ratio), typically ethylene glycol based (verify manual for specific Kawasaki coolant type).
Brake Fluid Spec:
DOT 4 (refer to manual for exact specification).
Fork Oil Spec:
SAE 10W (or equivalent viscosity) - capacity and level are critical and detailed in the manual.
Known Issues
Common Wear Items:
Clutch plates, brake pads, brake discs, chain and sprockets, fork seals, and wheel bearings are typical wear items subject to regular inspection and replacement.
Potential Electrical Issues:
While generally reliable, older bikes can develop issues with wiring harnesses, regulator/rectifier units, or battery connections. Detailed diagnostic steps are crucial.
Fuel System Maintenance:
Periodic cleaning of fuel injectors and throttle bodies can maintain optimal performance and fuel efficiency.
📚 Vehicle History
Brand Heritage
Kawasaki Legacy:
Kawasaki has a long history of producing powerful and innovative motorcycles, particularly in the sportbike and naked bike categories, dating back to the 1960s.
Model Evolution
Z Series Heritage:
The Z750 is part of Kawasaki's storied Z lineage, which began with the legendary Z1 in 1972, often credited with defining the superbike category.
Z750 Generations:
The first Z750 was introduced in the early 1970s. This 2007-2010 model represents the third generation (ZR750J), an evolution of the previous ZR750K/L, featuring styling and performance updates.
Production
Manufacturing Location:
Primarily manufactured in Japan by Kawasaki Heavy Industries.
🏆 Awards & Recognition
Recognitions
Industry Awards:
Specific industry awards for the Z750 (2007-2010) are not widely publicized, but it was generally well-received by motorcycle journalists for its blend of performance and value.
Ratings
Magazine Reviews:
Consistently praised for its strong inline-four engine, comfortable riding position for a sportbike, and attractive price point.
Certifications
Emissions Compliance:
Compliant with relevant emissions standards for its respective markets during the production years (e.g., Euro 3).
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