Kawasaki ZR750F ZR-7 Motorcycle Manual 1999-2003

Description

The Kawasaki ZR750F ZR-7 Factory Service Manual Provides detailed service information, step-by-step repair instruction and maintenance specifications for 1999-2003 Kawasaki ZR750F ZR-7 motorcycles.

1999 2000 2001 2002 2003

Table of Contents

General Information
Periodic Maintenance
Fuel System
Engine Top End
Clutch
Engine Lubrication System
Engine Removal/Installation
Crankshaft/Transmission
Wheels/Tires
Final Drive
Brakes
Suspension
Steering
Frame
Electrical System
Appendix

Index of Topics

Before Servicing
Model Identification
General Specifications
Unit Conversion Table
Periodic Maintenance Chart (United States, Canada Model)
Periodic Maintenance Chart (Other than United States Canada model)
Torque and Locking Agent
Specifications
Special Tools
Maintenance Procedure
Fuel System
Fuel Hose and Connection Check
Throttle Grip Play Check
Idle Speed check
Carburetor Synchronization Check
Air Cleaner Element Cleaning and Inspection
Evaporative Emission Control System Check
Engine Top End
Air Suction Valve Inspection
Valve Clearance Check
Cylinder Head Bolt Tightness Check
Clutch
Clutch Adjustment
Engine Lubrication System
Engine Oil Change and Oil Filter Replacement
Wheels/Tires
Tire Wear Inspection
Final Drive
Drive Chain Check
Brakes
Brake Fluid Level Inspection
Brake Fluid Change
Caliper Piston Seal and Dust Seal Check
Brake Pad Inspection
Master Cylinder Inspection
Brake Light Switch Check
Brake Hoses and Connections Check
Suspension
Front Fork Oil Change
Front Fork Oil Leak Check
Rear Shock Absorber Oil Leak Check
Swingarm Pivot Lubrication
Uni-Trak Linkage Lubrication
Steering
Steering Check
Steering Adjustment
Exploded View
Specifications
Special Tools
Throttle Grip and Cable
Throttle Grip Free Play Inspection
Throttle Grip Free Play Adjustment
Throttle Cable Installation
Throttle Cable Lubrication and Inspection
Choke Cable
Choke Cable Free Play Inspection
Choke Cable Free Play Adjustment
Carburetors
Idle Speed Inspection
Idle Speed Adjustment
Carburetor Synchronization Inspection
Carburetor Synchronization Adjustment
Service Fuel Level Inspection
Service Fuel Level Adjustment
Fuel System Cleaning and Inspection
Carburetor Cleaning
Air Cleaner
Air Cleaner Element Removal
Air Cleaner Element Installation
Air Cleaner Element Cleaning and Inspection
Breather Oil Draining
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Cleaning
Fuel Tap Inspection
Evaporative Emission Control System (California Model Only)
Parts Removal/Installation Notes
Hose Inspection
Separator Inspection
Separator Operation Test
Canister Inspection
Exploded View
Specifications
Special Tools and Sealants
Cylinder Head Cover
Cylinder Head Cover Removal
Cylinder Head Cover Installation
Clean Air System
Air Suction Valve Removal
Air Suction Valve Installation
Air Suction Valve Inspection
Vacuum Switch Valve Removal
Vacuum Switch Valve Installation
Vacuum Switch Valve Test
Clean Air System Hose Inspection
Camshaft Chain Tensioner
Camshaft Chain Tensioner
Removal
Camshaft Chain Tensioner
Installation
Camshaft Chain
Camshaft Removal
Camshaft Installation
Camshaft Assembly
Camshaft/Cap Clearance Inspection
Camshaft Chain Wear Inspection
Cylinder Head
Cylinder Head Compression
Measurement
Cylinder Head Removal
Cylinder Head Installation
Valves
Valve Clearance Inspection
Removal
Valve Installation
Valve Guide Removal
Valve Guide Installation
Valve Seat Inspection
Valve Seat Repair
Valve-to-Guide Clearance
Measurement (Wobble Method)
Cylinders and Pistons
Cylinder and Piston Removal
Cylinder and Piston Installation
Cylinder Wear
Piston Wear
Piston/Cylinder Clearance
Piston Ring/Ring Groove
Clearance
Piston Ring Groove Wear
Piston Ring Thickness
Piston Ring End Gap
Measurement
Muffler
Muffler Removal
Exhaust Pipe Installation
Silencer Removal
Muffler Installation
Exploded View
Specifications
Special Tool and Sealants
Clutch Lever and Cable Adjustment
Clutch Lever Position Adjustment
Clutch Lever Free Play Inspection
Clutch Leer Free Play Adjustment
Clutch Cover
Clutch Cover Removal
Clutch Cover Installation
Clutch Release Shaft Removal
Clutch Release Shaft Installation
Clutch
Clutch Removal
Clutch Installation
Clutch Plate Wear and Damage
Clutch Plate Warp
Clutch Spring Free Length Inspection
Clutch Housing Finger Damage
Clutch Hub Spline Damage
Exploded View
Specifications
Special Tools
Engine Oil and Filter
Engine Oil Level Inspection
Engine Oil Change and Oil Filter Replacement
Oil Pan
Oil Pan Removal
Oil Pan Installation
Oil Pump
Oil Pump Removal
Oil Pump Installation
Oil Screen Cleaning
Oil Pressure Measurement
Oil Pump Discharge Pressure
Relief Valve Inspection
Exploded View
Engine Removal/Installation
Engine Removal
Engine Installation
Exploded View
Specifications
Special Tools and Sealants
Secondary Shaft and Starter Clutch
Removal
Installation
Disassembly
Assembly
Crankcase Splitting
Crankcase Splitting
Crankcase Assembly
Crankshaft/Connecting Rod
Removal
Installation
Crankshaft/Connecting Rod
Cleaning
Connecting Rod Bend
Connecting Rod Twist
Connecting Rod Big End Side
Clearance-
Connecting Rod Big End Bearing
Insert Crankpin Wear
Crankshaft Main Journal/Bearing
Insert Wear
Crankshaft Runout
Crankshaft Side Clearance
Transmission
Shift Pedal Removal
Shift Pedal Installation
External Shift Mechanism
Removal
External Shift Mechanism
Installation
Transmission Shaft Removal
Transmission Shaft Installation
Transmission Shaft Disassembly
Transmission Assembly
Drive Shaft Gear Adjustment
Output Shaft Gear Adjustment
Shift Fork/Shift Drum Removal
Shift Fork/Shift Drum Installation
Shift Drum Disassembly
Shift Drum Assembly
Shift Fork Bending
Shift Fork Ear/Gear Shift Fork
Groove Wear
Shift Fork Guide Pin/Shift Drum
Groove Wear
Gear Dog/Gear Dog Hole
Damage
Ball Bearing, Needle Bearing, and Oil
Seal
Ball Bearing and Outer Race
Replacement
Ball and Needle Bearing Wear
Oil Seal Inspection
Exploded View
Specification
Special Tools
Wheels
Front Wheel Removal
Front Wheel Installation
Rear Wheel Removal
Rear Wheel Installation
Wheel Inspection
Axle Inspection
Balance Inspection
Balance Adjustment
Balance Weight Removal
Balance Weight Installation
Tires
Air Pressure Inspection
Tire Inspection
Tire Removal
Tire Installation
Tire Repair
Hub Bearing (Wheel Bearing)
Bearing Removal
Bearing Installation
Bearing Wear
Bearing Lubrication
Speedometer Gear Housing
Disassembly
Lubrication
Exploded View
Specifications
Special Tools
Drive Chain
Drive Chain Slack Inspection
Drive Chain Slack Adjustment
Wheel Alignment Inspection
Wheel Alignment Adjustment
Drive Chain Wear Inspection
Drive Chain Lubrication
Drive Chain Removal
Drive Chain Installation
Sprocket/Sprocket Coupling
Engine Sprocket Removal
Engine Sprocket Installation
Rear Sprocket/Coupling Removal
Rear Sprocket/Coupling Installation
Sprocket Wear Inspection
Rear Sprocket Warp Inspection
Coupling Bearing Removal
Coupling Bearing Installation
Coupling Bearing Inspection and Lubrication
Exploded View
Specifications
Special Tools
Brake Lever, Brake Pedal
Brake Lever Position Adjustment
Brake Pedal Position Inspection
Brake Pedal Position Adjustment
Brake Pedal Removal
Brake Pedal Installation
Brake Fluid
Brake Fluid Level Inspection
Brake Fluid Change
Brake Bleeding
Calipers
Caliper Removal
Caliper Installation
Caliper Disassembly
Caliper Assembly
Caliper Fluid Seal Damage
Caliper Dust Seal/Friction Boot Damage
Caliper Piston and Cylinder Damage
Caliper Holder Shaft Wear
Brake Pads
Brake Pad Removal
Brake Pad Installation
Brake Pad Inspection
Master Cylinder
Front Master Cylinder Removal
Front Master Cylinder Installation
Rear Master Cylinder Removal
Rear Master Cylinder Installation
Front Master Cylinder Disassembly
Rear Master Cylinder Disassembly
Master Cylinder Assembly
Master Cylinder Inspection
Brake Discs
Brake Disc Wear
Brake Disc Warp
Removal
Installation
Brake Hose Removal/Installation
Brake Hose Inspection
Exploded View
Specifications
Special Tools
Front Fork
Front Fork Oil Change
Front Fork Removal
Front Fork Installation
Front Fork Disassembly
Front Fork Assembly
Inner Tube/Outer Tube Inspection
Dust Seal Inspection
Fork Spring Inspection
Rear Shock Absorber
Rebound Damping Adjustment
Spring Preload Adjustment
Removal
Installation
Swingarm
Swingarm Removal
Swingarm Installation
Swingarm Bearing Removal
Swingarm Bearing Installation
Swingarm Bearing and Sleeve Inspection
Tie Rod/Rocker Arm
Tie Rod Removal
Tie Rod Installation
Rocker Arm Removal
Rocker Arm Installation
Rocker Arm and Tie Rod Bearing Inspection
Rocker Arm and Tie Rod Sleeve Inspection
Exploded View
Special Tools
Steering
Steering Inspection
Steering Adjustment
Steering Stem and Stem Bearing Removal
Steering Stem and Stem Bearing Installation
Steering Stem Bearing Lubrication
Steering Stem Warp
Handlebar
Handlebar Removal
Handlebar Installation
Exploded View
Seat
Seat Removal
Seat Installation
Side Cover
Left Side Cover Removal
Right Side Cover Removal
Fender
Rear Fender Rear Section Removal
Rear Fender Front Section Removal
Rear Fender, Front Section Installation
Parts Location
Exploded View
Specifications
Special Tools and Sealant
Wiring Diagram (United States, Canada)(ZR750-F1 – F2)
Wiring Diagram (Australia)(ZR750-F1 – F2)
Wiring Diagram (Netherlands Italy, United Kingdom)(ZR750-F1 ~ F2)
Wiring Diagram (Other’s)(ZR750-F1 – F2)
Wiring Diagram (Australia)(ZR750-F3 – )
Wiring Diagram (Other than Australia)(ZR750-F3 ~ )
Precautions
Electrical Wiring
Wiring Inspection
Battery
Battery Removal
Battery Installation
Electrolyte Filling (precautions before using the battery)
Initial Charge
Percussions
Interchangeability
Charging Condition Inspection
Refreshing Charge
Charging System
Alternator Rotor Removal
Alternator Rotor Installation
Alternator Inspection
Regulator/Rectifier Inspection
Charging Voltage (Regulator/Rectifier s Output Voltage) Inspection
Ignition System
Pickup Coil Removal
Pickup Coil Installation
Pickup Coil Inspection
Ignition Coil Removal
Ignition Coil Installation
Ignition Coil Inspection
Spark Plug Removal Installation
Spark Plug Cleaning, Inspection
Spark Plug Gap Inspection
IC Igniter Removal
IC Igniter Inspection
Electric Starter System
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
Starter Motor Assembly
Commutator Cleaning/Inspection
Armature Inspection
Starter Motor Brush Length
Brush Assembly Inspection
Brush Plate and Terminal Bolt Inspection
Starter Relay Inspection
Lighting System
Headlight Beam Adjustment
Headlight Unit Removal
Headlight Unit Installation
Headlight Bulb Replacement
Turn Signal Relay Inspection
Lighting System
Meters Gauges
Meter Unit Removal
Tachometer Inspection
Fuel Gauge Operation Inspection
Switches and Sensors
Rear Brake Light Timing Inspection
Rear Brake Light Timing Adjustment
Inspection
Fuel Level Sensor Inspection
Throttle Sensor Removal and Installation
Throttle Sensor Inspection
Throttle Sensor Position Adjustment
Carburetor Heater
Carburetor Heater Inspection
Normal Open Type Relay Inspection
Atmospheric Temperature Sensor Inspection
PTC Sensor (Carburetor Temperature Sensor) Inspection
Carburetor Heater Controller Inspection
Junction Box
Fuse Removal
Fuse Installation
Fuse Inspection
Fuse Circuit Inspection
Headlight Relay Starter Circuit Relay Circuit Inspection
Diode Circuit Inspection
Troubleshooting Guide
Cable, Wire, and Hose Routing