Kawasaki Z750 (ZR750) 2004-2008, Z1000 (ZR1000) 2003-2008 Repair Manual

The 2003-2008 Kawasaki ZR750, ZR1000 repair and service manual by Haynes covers :

• Kawasaki ZR750-J, 2004-2006
• Kawasaki ZR750-L, 2007-2008
• Kawasaki ZR750-M (ABS), 2007-2008
• Kawasaki ZR1000-A, 2003-2006
• Kawasaki ZR1000-B, 2007-2008
• Kawasaki ZR1000-C (ABS), 2007-2008

Book Excerpt: 2003-2008 Kawasaki Z750 (ZR750), Z1000 (ZR1000) Repair Manual ENGINE, CLUTCH AND TRANSMISSION

VALVE COVER NOTE: the valve cover can be removed with the engine in the frame. If the engine has been removed, ignore the steps which do not apply. REMOVAL

1. Remove the fuel tank (see Chapter 4), the thermostat housing and hoses (see Chapter 3), the air suction control valve and hoses, and the ignition coils and the coil wiring sub-loom (see Chapter 4). Make sure all wiring is clear of the cover.
2. On ZR750-L/M and ZR1000-B/C models, if the engine is in the frame unscrew the front bolt on each reed valve cover to free the shield bracket (see illustration).
3. Unscrew the valve cover bolts and lift the cover off the cylinder head (see illustrations). If it is stuck, do not try to lever it off with a screwdriver. Tap it gently around the sides with a rubber hammer or block of wood to dislodge it. Note the washers for the bolts and remove them if they are loose (see illustration 7.10).
4. Remove the rubber gasket noting how it locates (see illustration 7.9). If it is in any way damaged, deformed or deteriorated, replace it with a new one.
5. Remove the spark plug bore gaskets and replace them with new ones if necessary (see illustration). Note the four dowels that link the air system passages between the valve cover and cylinder head and remove them for safekeeping if they are loose (which is unlikely), taking care not to drop them if they are not in the valve cover.

BRAKES, WHEELS AND FINAL DRIVE

FRONT BRAKE DISCS INSPECTION

1. Inspect the surface of the disc for score marks and other damage. Light scratches are normal after use and won't affect brake operation, but deep grooves and heavy score marks will reduce braking efficiency and accelerate pad wear. If a disc is badly grooved it must be replaced with a new one.
2. The disc must not be machined or allowed to wear down to a thickness less than the service limit listed in this Chapter's Specifications. The minimum thickness is also stamped on the disc (see illustration). Check the thickness of the disc with a micrometer and replace it with a new one if necessary.
3. To check if the disc is warped, position the bike on an auxiliary stand with the front wheel raised off the ground. Mount a dial gauge to the fork leg, with the gauge plunger touching the surface of the disc about 10mm from its outer edge (see illustration). Rotate the wheel and watch the gauge needle, comparing the reading with the limit listed in the Specifications at the beginning of this Chapter. If the runout is greater than the service limit, check the wheel bearings for play (see Chapter 1). If the bearings are worn, install new ones (see Section 17) and repeat this check. If the disc runout is still excessive, a new pair of discs will have to be fitted.

Subject: 2003, 2004, 2005, 2006, 2007, 2008 Kawasaki Z750 (ZR750), Z1000 (ZR1000) service, maintenance, repair. ISBN-10: 1844257622 | ISBN-13: 9781844257621 | Haynes 4762