Target Audience:
Do-it-yourselfers and experienced mechanics.
Value Proposition:
Inexpensive way to keep the vehicle working properly, offering significant savings over dealership service costs.
Uniqueness:
Provides factory-level detail and accuracy, which is crucial for proper maintenance and repair of modern motorcycles.
Instruction Style:
Step-by-step instructions with highly detailed exploded pictures and diagrams.
Completeness:
Based on complete disassembly of the machine, ensuring all aspects are covered.
Primary Coverage:
2004 Kawasaki Z750 (ZR750-J1)
Secondary Coverage:
Potentially other early J-series Z750 models with similar architecture, though primarily focused on the J1 variant.
Estimated Page Count:
Approximately 400-600 pages (typical for a comprehensive factory service manual).
Type:
Factory Service Repair Workshop Manual
Engine Mechanical:
Top end, lubrication system, crankshaft, transmission, engine removal/installation.
Fuel System:
DFI (Digital Fuel Injection) system diagnostics, adjustments, and component repair.
Cooling System:
Radiator, coolant, fan, and related components.
Drivetrain:
Clutch operation and repair, final drive (chain and sprockets), transmission gear diagnostics.
Chassis And Suspension:
Wheels, tires, brakes (front and rear), suspension (forks and rear shock), steering.
Electrical System:
Wiring diagrams, ignition system, lighting, instrumentation, starting system, charging system.
Frame And Bodywork:
Frame inspection, removal/installation of body panels, and related hardware.
Maintenance:
Periodic maintenance schedules, fluid changes, filter replacements, chain adjustment.
Repair:
Step-by-step instructions for disassembly, repair, and reassembly of all major components.
Diagnostics:
Troubleshooting guides for common issues, DFI system error codes.
Adjustment:
Carburetor synchronization (if applicable, though this is DFI), chain tension, clutch lever free play.
Specifications:
Torque values, clearances, fluid capacities, electrical specifications.
Depth:
Comprehensive. Covers everything from basic fluid checks and adjustments to complete engine rebuilds, electrical troubleshooting, and chassis component overhaul.
Diagrams:
High-quality, detailed exploded views and diagrams for accurate part identification and assembly guidance.
Readability:
Designed for easy-to-read text sections.
Diagram Quality:
Top quality diagrams.
Printable:
All pages are printable.
Binding:
Digital (PDF) - no physical binding.
Paper Type:
Not Applicable (Digital Format)
Operating Systems:
Compatible with All Versions of Windows & Mac.
Reader Software:
Requires Adobe PDF Reader.
Extraction Software:
Requires WinZip or similar archiving software for download if compressed.
Delivery Method:
Instant Download, saving on postage and packaging.
Engine Type:
Liquid-cooled, 4-stroke, DOHC, inline-four cylinder.
Displacement:
738 cc (approximate, based on the Z750 model line).
Bore X Stroke:
Typically around 68.0 x 51.2 mm for this engine family.
Compression Ratio:
Likely around 10.1:1 to 11.0:1.
Horsepower:
Approximately 104-110 PS (76.5-81 kW) at 10,500 rpm (typical for this generation).
Torque:
Approximately 77-80 Nm (57-59 lb-ft) at 8,000 rpm (typical for this generation).
Fuel Delivery:
DFI (Digital Fuel Injection) with sub-throttle valves.
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2. For specific octane, refer to manual.
Ignition System:
TCBI (Transistor Controlled Ignition) with electronic advance.
Lubrication Type:
Wet sump.
Oil Type Specification:
Kawasaki K-Tech 10W-40 Semi-Synthetic or equivalent API SG/SH/SJ/SL, JASO MA.
Length:
Approximately 2,085 mm (82.1 in).
Width:
Approximately 770 mm (30.3 in).
Height:
Approximately 1,055 mm (41.5 in).
Wheelbase:
Approximately 1,430 mm (56.3 in).
Dry Weight:
Approximately 197 kg (434.3 lbs).
Wet Weight:
Approximately 213 kg (470 lbs) (with all fluids).
Load Capacity:
Typically 200 kg (440 lbs) including rider and luggage.
Crash Test Ratings:
Not applicable for motorcycles in the same way as cars.
Braking System:
Dual semi-floating 300 mm petal discs with dual piston calipers (front), Single 240 mm petal disc with dual piston caliper (rear).
ABS:
Optional ABS variant may be available depending on market, but not standard.
Lighting:
Halogen headlight, LED taillight.
Indicators:
Standard turn signals front and rear.
Instrumentation:
Digital speedometer, analog tachometer, odometer, trip meter, clock, coolant temperature warning light, fuel injection warning light, neutral indicator, high beam indicator.
ABS Availability:
ABS was an optional feature for some markets and specific trim levels of the Z750 in this generation.
Connectivity Features:
None (N/A for this model year).
Oil Change Interval:
Every 6,000 km (3,700 miles) or 6 months, whichever comes first.
Spark Plug Replacement:
Every 12,000 km (7,500 miles) or 12 months.
Air Filter Cleaning:
Every 6,000 km (3,700 miles), replace as needed.
Valve Clearance Check:
Every 12,000 km (7,500 miles) or 12 months.
Chain Cleaning Lubrication:
Every 1,000 km (600 miles) or after riding in rain or wet conditions.
Coolant Type:
Kawasaki Coolant Type 2 (50/50 mix of ethylene glycol and deionized water) or equivalent.
Brake Fluid Type:
DOT 4 brake fluid.
Engine Oil Capacity With Filter:
Approximately 3.4 Liters (3.6 US qt).
Engine Oil Capacity Without Filter:
Approximately 3.0 Liters (3.2 US qt).
Coolant Capacity:
Approximately 1.8 Liters (1.9 US qt).
Common Wear Items:
Clutch plates, chain and sprockets, wheel bearings, fork seals, brake pads.
Potential Electrical:
Voltage regulator/rectifier failure, stator coil issues are not uncommon in some Kawasaki models of this era. Wiring harness chafing can also occur.
Fuel System Concerns:
While DFI is generally reliable, occasional issues with fuel injectors or the throttle position sensor can arise. Fuel pump reliability is also a consideration.
Engine Performance Issues:
Carbon buildup in combustion chambers, especially if ridden primarily in city conditions at lower RPMs. This can lead to slight performance degradation or rough idling.
Manufacturer:
Kawasaki Heavy Industries Motorcycle & Engine Company.
Brand Focus:
Known for performance-oriented motorcycles across various categories, including sportbikes, nakeds, and cruisers.
Predecessors:
The Z750 lineage traces back to earlier Kawasaki inline-four motorcycles, evolving from models like the Z650 and Z750 Ltd.
Development Focus:
The ZR750-J generation (introduced around 2004) represented a significant update, focusing on modern styling, improved chassis, and updated DFI.
Production Period:
The Z750 model line, in various iterations, has been in continuous production since the 1970s. The ZR750-J generation was produced from roughly 2004 to 2007.
Manufacturing Location:
Primarily manufactured in Japan.
Industry Awards:
The Z750 line has generally been well-received for its blend of performance, styling, and value, often earning praise in motorcycle publications for its class.
Owner Satisfaction:
Typically scores well with owners for its strong engine performance and engaging riding experience.
Emissions Compliance:
Complies with relevant emissions standards for its model year and region of sale.
