Kawasaki Z750 ZR750 2007-2012 Workshop Repair Service Manual

Name: Kawasaki Z750 ZR750 2007-2012 Workshop Repair Service Manual
Brand: Kawasaki
SKU: 87074
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Typ: Motorcycle

Anbieter:

Kawasaki

Art.-Nr: 87074

Stichworte: 2007 2008 2009 2010 2011 2012 Kawasaki Misc Motorcycle Motorcycles Z750 ZR750

Produktvarianten

Beschreibung

The Z750 (ZR750), model designation ZR750K, is a naked sportbike that was produced between 2007 and 2012. Known for its aggressive styling and balanced inline-four engine performance, it was designed as a versatile machine for street riding, often compared to competitors like the Yamaha FZ6/FZ8 and Suzuki Bandit series. This model features a liquid-cooled, 749 cc inline-four engine with fuel injection, producing approximately 106 PS, paired with a 6-speed transmission and final chain drive. Its engineering emphasizes user-friendly ergonomics and a responsive power delivery, making it a popular choice for riders seeking a blend of performance and everyday usability. This comprehensive workshop repair service manual in English provides detailed guidance for the maintenance and repair of the Z750. It covers all essential systems, including complete engine mechanical and electrical procedures, fuel system components, transmission, suspension, brakes, cooling system, exhaust, frame, bodywork, electrical systems, and wheels/tires. The manual includes routine maintenance, troubleshooting diagnostics, major repair procedures, and component removal/installation steps, along with critical torque specifications and wiring diagrams. Its purpose is to equip owners, mechanics, and technicians with the necessary information to effectively service and maintain the vehicle, ensuring optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

Z750 (ZR750)

Model Designation:

ZR750K

Production Years Covered:

2007, 2008, 2009, 2010, 2011, 2012

Primary Market:

Global (Europe, Asia, North America variations exist)

👋 Introduction

Market Position

Category:

Naked Sportbike / Streetfighter

Target Audience:

Riders seeking a versatile, performance-oriented motorcycle with a focus on street riding and occasional track use.

Competitive Analysis

Competitors:

Yamaha FZ6/FZ8, Suzuki Bandit 650/1250, Honda CB600F Hornet, Triumph Street Triple.

Key Features

Engine Layout:

Inline-four cylinder, liquid-cooled

Design Philosophy:

Balanced performance, aggressive styling, user-friendly ergonomics.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Repair Service Manual

Language:

English

Format:

PDF Download

Completeness:

Comprehensive

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of all engine components including cylinder head, valves, piston, crankshaft, connecting rods, camshafts, and oil pump.

Engine Electrical:

Ignition system (spark plugs, coils, timing), fuel injection system (ECU, injectors, sensors), charging system (stator, regulator/rectifier), starting system (starter motor, solenoid), wiring diagrams.

Fuel System:

Fuel tank, fuel pump, fuel filter, fuel injectors, fuel pressure regulator, throttle body assembly.

Transmission:

Clutch operation, gearshift mechanism, internal transmission components, lubrication, removal and installation.

Suspension:

Front forks (disassembly, seal replacement, oil level and type, adjustment), rear shock absorber (removal, installation, adjustment), linkage system.

Brakes:

Front and rear brake system components (calipers, master cylinders, brake lines, pads, discs), hydraulic system bleeding, ABS system (if equipped - diagnostics and bleeding procedures).

Cooling System:

Radiator, coolant hoses, water pump, thermostat, fan operation, coolant type and capacity.

Exhaust System:

Exhaust pipes, muffler, catalytic converter, exhaust gasket replacement.

Frame And Bodywork:

Frame inspection, body panel removal and installation, fairings, seat, fuel tank mounting.

Electrical System And Lighting:

Headlight, taillight, turn signals, brake lights, dashboard instrumentation, horn, battery maintenance, fuses, relays.

Wheels And Tires:

Tire pressure, wheel bearing inspection, tire replacement, wheel balancing.

Procedures Included

Routine Maintenance:

Oil and filter changes, air filter cleaning/replacement, spark plug checks and replacement, chain lubrication and adjustment, brake fluid checks, coolant level checks.

Troubleshooting:

Diagnostic flowcharts for common starting issues, running problems, electrical faults, and performance degradation.

Major Repairs:

Engine rebuilds, transmission overhaul, suspension fork rebuilds, brake system servicing.

Component Removal And Installation:

Detailed steps for removing and reinstalling all major and minor components.

Wiring Diagrams:

Complete, high-resolution wiring schematics for all electrical systems.

Torque Specifications:

Essential torque values for all fasteners to ensure correct assembly and prevent damage.

Technical Depth

Diagnostic Capability:

Advanced diagnostic procedures, fault code interpretation (if applicable for ECU), sensor testing.

Rebuild Procedures:

Detailed, step-by-step instructions for complete engine and component rebuilds.

Measurement And Calibration:

Specifications for critical measurements (e.g., piston ring gap, bearing clearances) and calibration procedures.

📊 Manual Specifications

File Format

File Type:

PDF

Searchability:

Likely text-searchable PDF (dependent on original document quality)

Printable:

Yes

Page Count:

Estimated 400-600 pages (typical for this type of comprehensive manual)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 4-stroke, DOHC, 4-valve per cylinder, inline-four

Displacement:

749 cc (750cc class)

Bore X Stroke:

68.4 mm x 50.9 mm

Compression Ratio:

11.5:1

Performance

Horsepower:

Approximately 106 PS (104.5 bhp / 78 kW) at 10,500 rpm (claimed)

Torque:

Approximately 77.0 Nm (56.8 lb-ft) at 8,000 rpm (claimed)

Fuel System

Fuel Delivery:

Fuel Injection with Digital Ignition (TCBI)

Throttle Control:

Dual throttle valves (Keihin)

Lubrication

Oil Type:

SAE 10W-40 API SG or SH

Oil Capacity W Filter:

Approx. 3.4 Liters (3.6 US qt)

🔧 Transmission

Standard

Type:

6-speed constant mesh

Clutch:

Wet, multi-plate

Final Drive:

Sealed chain

Features

Gear Ratios:

Specific gear ratios will be detailed in the manual for each gear.

Transmission Oil Type:

API GL-4 SAE 80W-90 or API GL-4 SAE 85W-90

📐 Dimensions

Exterior

Length:

Approx. 2,105 mm (82.9 in)

Width:

Approx. 760 mm (29.9 in)

Height:

Approx. 1,090 mm (42.9 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

Dry Weight:

Approx. 203 kg (447.5 lbs)

Curb Weight:

Approx. 225 kg (496 lbs) with all fluids

Fuel Tank Capacity:

15 Liters (3.9 US gal)

Wheels And Tires

Front Tire:

120/70ZR17 M/C (58W)

Rear Tire:

180/55ZR17 M/C (73W)

Front Wheel:

17M/C x MT3.50

Rear Wheel:

17M/C x MT5.50

Wheelbase Spec:

1,440 mm (56.7 in)

🛡️ Safety Features

Ratings

ABS Availability:

Optional (ABS models available)

Active Features

Braking System:

Dual front 300mm petal discs with 4-piston calipers, single rear 250mm petal disc with 2-piston caliper.

Suspension Type:

Front: 41mm telescopic fork, adjustable preload. Rear: Uni-Trak, gas-charged shock with adjustable preload and rebound damping.

Passive Features

Lighting:

Multi-reflector headlight, LED taillight.

💡 Technology Features

Infotainment

Instrument Cluster:

Digital speedometer, analog tachometer, multi-function LCD display (odometer, trip meters, fuel gauge, clock, etc.).

Driver Assistance

ABS:

Available ABS system for enhanced braking safety.

Connectivity

ECU Control:

Engine Control Unit (ECU) manages fuel injection and ignition timing for optimal performance and emissions.

🔧 Maintenance

Service Intervals

First Service:

1,000 km (600 miles) or 6 months (whichever comes first) - includes oil and filter change, chain adjustment, inspection of all critical fasteners and systems.

Subsequent Service:

Every 6,000 km (3,750 miles) or 12 months - includes standard checks, oil and filter, air filter, spark plugs at specific intervals (e.g., 12,000 km), coolant change (e.g., every 24,000 km).

Fluid Specifications

Engine Oil:

SAE 10W-40, API SG or SH (refer to manual for exact specifications and alternatives).

Coolant:

Kawasaki Genuine Coolant or equivalent ethylene glycol-based coolant with demineralized water (50:50 mix).

Brake Fluid:

DOT 4

Fork Oil:

Typically Showa SS-01 or equivalent SAE 5W fork oil. Exact type and quantity per leg specified in manual.

Known Issues

Common Wear Items:

Clutch plates, brake pads, chain and sprockets, fork seals, wheel bearings.

Potential Electrical:

Less common, but regulator/rectifier failure can occur under sustained high electrical load or due to heat buildup. Wiring loom connections should be checked for corrosion.

Engine Performance Notes:

Some owners report a slightly snatchy throttle response at low RPMs, often mitigated by fuel management adjustments or ECU remapping. Regular maintenance of the fuel injection system is key.

Suspension Tuning:

The stock suspension is often considered adequate but can be improved with aftermarket components or precise tuning of the existing adjusters for aggressive riding styles.

📚 Vehicle History

Brand Heritage

Kawasaki Legacy:

Kawasaki Heavy Industries, Ltd. has a long and storied history in motorcycle manufacturing, known for its performance-oriented and innovative machines, particularly in the sportbike and powerful motorcycle segments.

Model Evolution

Z Series Heritage:

The 'Z' designation represents Kawasaki's lineage of performance motorcycles, dating back to the iconic Z1 in the 1970s. The Z750 evolved from previous generations of 750cc inline-fours, offering a blend of accessible performance and street-focused usability.

Production

Manufacturing Location:

Primarily Japan

Market Introduction Period:

The Z750 was a significant model in Kawasaki's lineup during the mid-2000s, popular in European and Asian markets before a more substantial presence in North America.

🏆 Awards & Recognition

Recognitions

Market Reception:

Generally well-received for its value proposition, offering a potent inline-four engine and sharp styling at a competitive price point.

Ratings

Performance Reviews:

Praised for its smooth power delivery and enjoyable handling characteristics for street riding.