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Z750R ABS
Motorcycle
Assembly & Preparation
Manual
Foreword
In order to ship Kawasaki vehicles as efficiently as possible, they are partially disassembled before crating. Since some of the most
commonly removed parts have a direct bearing on a vehicles reliability and safety, conscientious pre-sale assembly and preparation becomes extremely important. Good setup procedures can prevent needless warranty claims
and give customers a greater sense of confidence in Kawasaki and their Kawasaki Dealers.
This Assembly and Preparation Manual explains step by step procedures of the following
items for all Kawasaki Z750R and Z750R ABS.
1. Uncrating
2. Assembly
3. Preparation
WARNING
WARNING indicates a hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, could result
in minor or moderate injury.
NOTICE
NOTICE is used to address practices not
related to personal injury.
NOTE
The selling dealer assumes sole responsibility for any unauthorized modifications prior to
sale. Refer to your Service Binder for any Service Bulletins specifying Factory Directed Modifications (Special Claims) which must be performed before the vehicle is ready for sale.
Whenever you see the following symbols
heed their instructions! Always follow safe
operating and maintenance practices.
DANGER
DANGER indicates a hazardous situation which, if not avoided, will result in
death or serious injury.
Sep., 2010
Table of Contents
Uncrating ......................................................................................
Opening Crate .............................................................................
Parts Check .................................................................................
Assembly ......................................................................................
Handlebar....................................................................................
Handlebar Weight........................................................................
Clutch Cable................................................................................
Rear View Mirrors (Left and Right) ..............................................
Seat Under Cover........................................................................
Preparation ...................................................................................
Battery Service ............................................................................
Coolant ........................................................................................
Front Brake Fluid.........................................................................
Rear Brake Fluid .........................................................................
Brake Disc Cleaning ....................................................................
Clutch Lever and Cable ...............................................................
Drive Chain..................................................................................
Front Fork ....................................................................................
Rear Shock Absorber ..................................................................
Tire Air Pressures........................................................................
Fuel .............................................................................................
Engine Oil (4-stroke) ...................................................................
Throttle Grip and Cable ...............................................................
Rear Brake Light Switch ..............................................................
Idle Speed Adjustment ................................................................
Headlight Aim ..............................................................................
Digital Meter ................................................................................
Fastener Check ...........................................................................
Standard Torque Table ................................................................
Test Ride the Motorcycle .............................................................
A & P Check List .........................................................................
3
3
5
5
5
6
6
7
7
8
8
12
15
17
18
18
19
21
22
22
22
23
24
24
25
25
25
28
30
30
30
UNCRATING 3
Uncrating
Opening Crate
WARNING
Crates have sharp edges and may have
nails or screws that can cause cuts and
injury. Always wear protective gloves,
boots and eye protection when uncrating to prevent injury.
WARNING
The steel crate panel plates and fasteners have sharp edges. Always wear protective gloves, boots and eye protection
when uncrating to prevent injury.
NOTICE
NOTE
Remove the dummy bolts after rolling the vehicle off the crate base.
4 UNCRATING
A. Rubber Band
B. Protective Cover
ASSEMBLY 5
Parts Check
the parts box, and check the parts against the illustrations. There may be minor differences
Open
between these illustrations and the actual vehicle parts. In the following charts under Remarks, D
= diameter in millimeters, and L = length in millimeters.
No.
Part Name
1 Weight, Handlebar
Weight Screw, Handlebar
Handelebar Clamp Bolt, Socket
Plastic Plug, Clamp Bolt
2 Rear View Mirror, LH & RH
Wiring Clamp, Plastic
3 Cover, Seat Under
4 Battery Electrolyte, YTX9-BS
5 Owners Manual
Assembly
Handlebar
Handlebar Installation
A. Dummy Bolts
B. Top Handlebar Clamp
Qty
1
1
2
4
2
1
1
1
1
Remarks
D = 8, L = 45
D = 8, L = 30
D = 14.5
12 V 8 Ah
6 ASSEMBLY
A. Plastic Plugs
B. Top Handlebar Clamp
Handlebar Weight
Clutch Cable
A.
B.
C.
D.
Clutch Cable
Adjuster
Cable Tip
Clutch Lever
ASSEMBLY 7
A. Clutch Cable
B. Left Switch Housing Harness
C. Cable/Wiring Clamp (Steel)
A. Stay
B. Mirror
and adjustment of the left side mir Installation
ror is common with the right side. Follow the
procedure specified for the right side.
NOTE
8 PREPARATION
Preparation
Battery Service
Battery Removal
The battery used in this motorcycle is a sealed
type and never needs to be refilled. Follow the
procedure for activating a new battery to ensure
the best possible battery performance.
Insert the ignition key into the seat lock located under the left seat cover (rear fairing).
A. Riders Seat
B. Seat Lock Cable Ring
the seat under cover mounting bolts
Remove
(D = 6, L = 18) (2).
the seat bracket mounting bolts (D =
Remove
6, L = 14) (4), then move the seat bracket.
A. Seat Lock
B. Ignition Key
the key clockwise while pulling up the
Turn
passengers seat.
A. Passengers Seat
B. Pull up
C. Turn the Key
the riders seat lock cable ring, and then
Pull
remove the riders seat by pulling the rear of
it up and backward.
PREPARATION 9
NOTICE
Do not remove the aluminum sealing
sheet from the filler ports until just prior
to use. Be sure to use the dedicated
electrolyte container for correct electrolyte volume.
the battery on a level surface.
Place
to see that the sealing sheet has no
Check
peeling, tears, or holes in it.
Remove the sealing sheet.
A.
B.
C.
D.
NOTE
Stopper
Fuse Box
Pull
Battery
If the sealing
sheet has leaked air into the battery, it may
require a longer initial charge.
Battery Activation
Electrolyte Filling
A. Sealing Sheet
B. Filler Ports
the electrolyte container from the
Remove
vinyl bag.
the strip of caps from the container
Detach
and set aside, these will be used later to seal
the battery.
NOTE
Battery Specifications
Make
Battery Type
Battery Capacity
Electrolyte Capacity
Battery/Electrolyte Set P/No.
GS Yuasa
YTX9-BS
12 V 8 Ah
0.40 L
26012-0088
10 PREPARATION
A. Strip of Caps
B. Sealed Cells
A. Air Bubbles
B. Tap the Container
NOTICE
Removal of the container before it is
completely empty can shorten the service life of the battery.
NOTE
NOTE
A. Strip of Caps
PREPARATION 11
Charging
NOTICE
Once the strip of caps is installed onto
the battery, never remove the caps, nor
add water or electrolyte to the battery.
NOTE
NOTE
Battery Installation
Kawasaki-recommended chargers:
Battery Mate 150-9
OptiMate PRO 4-S/PRO S/PRO 2
Yuasa MB-2040/2060
Christie C10122S
the above chargers are not available, use
Ifequivalent
one.
Let
battery
30 minutes after initial charge,
then check sitvoltage
using a voltmeter. (Voltage immediately after charging becomes temporarily high. For accurate measuring, let the
battery sit for given time.)
A. Battery
B. Positive Cable (+)
C. Negative Cable ()
down the battery to a rear side and
Throw
route the (+) cable through the guide in the
battery case.
Position the () negative lead connector at the
rear of the battery.
12 PREPARATION
A.
B.
C.
D.
Battery
Positive Cable (+)
Negative Cable ()
Route the (+) cable through the guide
in the battery case.
It
NOTE
A.
B.
C.
D.
Reserve Tank
F (Full) Level Line
L (Low) Level Line
Seat Cover (Right)
Coolant filling
Coolant
Coolant Level Inspection
NOTE
PREPARATION 13
A. Screw Rivet
B. Central Pin
C. Turn the screw rivet.
(rear fairing).
Remove the right seat cover by pulling it outward to clear the projections.
A. Screw Rivet
B. Central Pin
C. Push in.
A.
B.
C.
D.
Bolt (D = 6, L = 14)
Screw Rivets
Seat Cover (Right)
Projections
NOTE
A.
B.
C.
D.
Cap
F (Full) Level Line
L (Low) Level Line
Reserve Tank
14 PREPARATION
the cap.
Install
Insert
the
projections of the right seat cover
into the grommets.
A.
B.
C.
D.
Cap
Seat Cover (Right)
Projections
Grommets
the bolt.
Reinstall the right side cover, mounting bolt
(D = 5, L = 16) and flat washer (D = 20), and
tighten the bolt.
Reinstall the sub-right side cover and mounting bolt (D = 6, L = 18), and tighten the bolt.
A.
B.
C.
D.
E.
Fuse Box
Seat Bracket
Passengers Seat Lock Cable
Riders Seat Lock Cables
Clamp (Plastic) Route the riders seat
lock cables in the clamp.
NOTE
A. Seat Bracket
B. Seat Bracket Mounting Bolts (D = 6, L
= 14)
C. Seat Under Cover
D. Seat Under Cover Mounting Bolts (D
= 6, L = 18)
the tab on the front of the riders seat
Insert
into the slot in the fuel tank bracket.
the hooks at the rear of the riders seat
Insert
into the latches, projections into the holes,
and push down the rear part of the riders seat
until the lock clicks.
PREPARATION 15
NOTE
from the seat lock, turn it lightly counterclockwise while pulling it out.
A. Passengers Seat
B. Tab
C. Slot
D. Hook
E. Projections
F. Holes
G. Latch
up the passengers seat to make sure it
Pull
is securely locked.
Pull out the ignition key from the seat lock.
16 PREPARATION
WARNING
Brake fluid that is contaminated by
moisture or dirt, mixed or contains air
has a lower boiling point and can cause
the brake to be ineffective or fail, and it
may cause rubber parts to deterioate,
resulting in an accident causing injury
or death. Never reuse old brake fluid.
Do not use fluid from a container that
has been left unsealed or that has been
open for a long time. Do not mix two
types and brands of fluid for use in the
brake. Dont leave the reservoir cap off
for any length of time to avoid moisture
contamination of the fluid. Dont add or
change the fluid in the rain or when a
strong wind is blowing.
NOTICE
Brake fluid quickly ruins painted surfaces. Wipe up any spilled fluid immediately.
the brake lever several times.
Operate
If
it
feels
brake line.spongy, there might be air in the
Ifline.necessary, bleed the air in the front brake
check for fluid leakage around the fit Also
tings.
NOTE
Tighten
torque.
PREPARATION 17
level lines.
Reinstall the diaphragm and reservoir cap.
Tighten the screws to the specified torque.
Torque: 1.5 Nm (0.15 kgfm, 13 inlb)
NOTICE
Brake fluid quickly ruins painted surfaces. Wipe up any spilled fluid immediately.
NOTE
A.
B.
C.
D.
18 PREPARATION
NOTE
WARNING
An anticorrosive treatment applied to
the brake discs will increase braking
distance and can cause an accident
resulting in serious injury or death. Remove the anticorrosive treatment using
an oilless solvent.
PREPARATION 19
Drive Chain
Drive Chain Slack and Wheel Alignment
Inspection
WARNING
A. Adjuster
B. Free Play: 2 3 mm (0.08 0.12 in.)
the free play is incorrect, adjust the free
Ifplay.
Before
NOTE
A. Adjusting Nuts
B. Clutch Cable
WARNING
NOTE
20 PREPARATION
WARNING
A.
B.
C.
D.
A.Marks
B.Notch
C.Drive Chain Adjuster (Left and Right)
D.Drive Chain Adjuster Locknut (Left and
Right)
E. Indicator
NOTE
A loose axle nut can lead to an accident resulting in serious injury or death.
Tighten the axle nut to the proper torque
and be sure the cotter pin is installed
correctly.
the wheel alignment.
Check
Install a new cotter pin.
NOTE
A. Cotter Pin
B. Turning Clockwise
PREPARATION 21
WARNING
If both spring preload adjusters and
both rebound and compression damping adjusters are not adjusted equally,
handling may be impaired and a hazardous condition may result. Set all
suspension adjusters equally to the recommended settings.
A. Cotter Pin
B. Nut
Front Fork
Spring Preload Adjustment
NOTICE
A. Spring Preload Adjuster
in the spring preload adjusters to in Turn
crease spring force and out to decrease
spring force. Adjust the spring preload to the
standard setting position.
NOTICE
The right and left fork tubes must be adjusted evenly.
NOTICE
Do not force to turn the rebound damping adjuster from the fully seated position or the adjusting mechanism may be
damaged.
22 PREPARATION
Fuel
WARNING
greatest.
Turn the rebound damping adjuster counterclockwise to decrease damping force.
To adjust the rear shock absorber rebound
damping, turn the rebound damping adjuster
with a screwdriver. Adjust the rebound damping to the standard setting position.
NOTICE
Do not force to turn the rebound damping adjuster from the fully seated position or the adjusting mechanism may be
damaged.
PREPARATION 23
A.
B.
C.
D.
Type:
NOTICE
If the engine is run without oil, it will be
severely damaged.
the engine and run it for several minutes
Start
at idle speed. Stop the engine, then wait sev-
24 PREPARATION
A.
B.
C.
D.
Decelerator Cable
Accelerator Cable
Adjusters
Locknuts
A. Throttle Grip
B. 2 3 mm (0.08 0.12 in.)
WARNING
Operation with incorrectly routed, improperly adjusted or damaged cables
could result in an unsafe riding condition. Be sure the cables are routed
correctly, properly adjusted and are not
damaged in any way.
A.
B.
C.
D.
NOTICE
To avoid damaging the electrical connections inside the switch, be sure that
the switch body does not turn during adjustment.
PREPARATION 25
A. Horizontal Adjuster
Vertical Adjustment
change.
With the engine idling, turn the handlebar to
each side. If handlebar movement changes
the idle speed, check the throttle cable routing
and free play.
WARNING
Operation with incorrectly routed or
damaged throttle cable could result in
an unsafe riding condition. Be sure the
throttle cable is routed correctly, properly adjusted and is not damaged in any
way.
A. Vertical Adjuster
NOTE
Headlight Aim
The headlight beam is adjustable both horizontally and vertically. Headlight aim must be
correctly adjusted for safe riding as well as oncoming drivers. In most areas it is illegal to ride
with improperly adjusted headlights.
Horizontal Adjustment
Digital Meter
Check the Unit Setting: mph, km/h
The mphkm/h display can alternate between
English and metric modes (mph and km/h) in
the digital meter. Make sure that mph or km/h
according to local regulations is correctly displayed before sale.
Turn the ignition switch ON.
Display the odometer in the digital meter.
The mphkm/h (or F/C temperature) display
shifts by pushing the RESET button while the
MODE button pushed in.
26 PREPARATION
A. mphkm/h Display
B. F /C Display
mphkm/h (and F/C temperature) dis The
play shifts as follows.
NOTE
PREPARATION 27
28 PREPARATION
Fastener Check
torque values listed are for assembly and preparation items only, see the appropriate Service
The
Manual for a more comprehensive list. Check tightness of all fasteners that are in the table before
retail delivery. Also check to see that each cotter pin or circlip is in place.
PREPARATION 29
No.
Fastener
Steering
1 Handlebar clamp bolt
Brake
2 Front master cylinder bleed valve
3 Front master cylinder clamp bolt
4 Front caliper bleed valve (Left and Right)
5 Front caliper mounting bolt (Left and Right)
6 Rear caliper bleed valve
7 Rear caliper mounting bolt
8 Rear caliper pin bolt
9 Rear master cylinder mounting bolt
Wheels
10 Front axle clamp bolt (Right)
11 Front axle
Suspension
Front fork lower clamp bolt (Middle, Left and
12
Right)
Front fork lower clamp bolt (Upper, Lower, Left
13
and Right)
14 Rear shock absorber mounting nut (Lower)
15 Tie-rod nut
16 Swingarm pivot shaft locknut
17 Swingarm pivot shaft nut
Others
18 Front footpeg bracket bolt (Left and Right)
19 Rear footpeg bracket bolt (Left and Right)
20 Engine oil drain plug
Rear view mirror upper hexagonal area (Left
21
and Right)
Rear view mirror lower hexagonal area (Left
22
and Right)
Cotter Pins or Circlips
23 Rear axle nut cotter pin
24 Rear master cylinder rod cotter pin
25 Front footpeg pin circlip (Left and Right)
26 Rear footpeg pin circlip (Left and Right)
Nm
Torque
kgfm
ftlb
25
2.5
18
7.8
11
7.8
34
7.8
27
22
25
0.80
1.1
0.80
3.5
0.80
2.8
2.2
2.5
69 inlb
97 inlb
69 inlb
25
69 inlb
20
16
18
20
127
2.0
13.0
15
94
17.5
1.78
13
25
2.5
18
34
59
98
108
3.5
6.0
10
11.0
25
44
72
80
25
25
29
2.5
2.5
3.0
18
18
21
18
1.8
13
30
3.1
22
Remarks
AL
AL: Tighten the two clamp bolts alternately two times to ensure even tightening torque.
S: Tighten the upper/front clamp bolt first, and then the lower/rear clamp bolt.
30 PREPARATION
General Fasteners
Threads
dia.
(mm)
5
6
8
10
12
14
16
18
20
Torque
Nm
kgfm
ftlb
3.4 4.9
5.9 7.8
14 19
25 34
44 61
73 98
115 155
165 225
225 325
0.35 0.50
0.60 0.80
1.4 1.9
2.6 3.5
4.5 6.2
7.4 10.0
11.5 16.0
17.0 23.0
23.0 33.0
30 43 inlb
52 69 inlb
10.0 13.5
19.0 25
33 45
54 72
83 115
125 165
165 240
Control Cables:
Throttle control cables must work without
binding in any steering position.
Steering:
Action is free from lock-to-lock.
Suspension:
Check operation front and rear.
Engine:
Electric starter works properly and engine
starts promptly. Good throttle response and
return.
Transmission and Clutch:
Smooth operation.
Brakes:
Adequate, smooth stopping power, No drag.
Digital Meter:
Check operation
Electrical System:
Headlight - check high and low beams.
Taillight - check operation.
Brake Light - check operation.
Turn Signal Lights - check operation.
Horn - check operation.
Instrument Lights and Indicator Lights Check operation.
Engine Stop Switch Works:
Starter Interlock Switch Works:
No Unusual Noises:
No Fuel, Oil, Brake Fluid, or Coolant
Leaks:
PREPARATION COMPLETE.
WARNING
New tires are slippery and may cause
loss of control and serious injury or
death. A break-in period of 160 km (100
miles) is necessary to establish normal tire traction. During break-in, avoid
sudden and maximum braking, acceleration, and hard cornering.
MODEL APPLICATION
Year
2011
2011
Model
ZR750NBF
ZR750PBF
Name
Z750R
Z750R ABS