Kawasaki ZR550 & 750 Zephyr Service Manual – PDF DOWNLOAD

Description

Kawasaki ZR550 & 750 Zephyr Service Manual – PDF DOWNLOAD

DESCRIPTION:

Kawasaki ZR550 & 750 Zephyr Service Manual – PDF DOWNLOAD

Models covered
ZR550 В Zephyr. 553сс. UK 1991 to 1997
ZR550 В Zephyr. 553сс. US 1990 to 1993
ZR750 С Zephyr. 738сс. UK 1991 to 1996
ZR750 С Zephyr. 738сс. US 1991 to 1993
ZR750 D Zephyr. 738сс. UK 1996 to 1997

INTRODUCTION

Kawasaki is а Company of eontradietions. lt is the smallest of the Ьig four Japanese manufaeturers but the Ьiggest eompany, it was the last of the four to make and market motoreyeles yet it owns the oldest name in the Japanese industry, and it was the first to set up а faetory in the USA. Kawasaki Heavy lndustries, of whieh the motorcycle operation is but а small eomponent, is а massive eompany with its heritage firmly in the old heavy industries like shipbuilding and railways; nowadays it is as mueh involved in aerospaee as in motoreyeles. ln faet it may Ье beeause of this that Kawasaki’s motoreyeles have always been quirky, you get the impression that they are designed Ьу а small group of enthusiasts who are given an admiraЫy free hand.

• More realistieally, it may Ье that Kawasaki’s designers have experienee with techniques and materials from other engineering disciplines. Either way, Kawasaki have managed to Ье the factory who surprise us more than the rest. Quite often, they do this Ьу totally ignoring а market segment the others are scrabЫing over, but more often they hit us with pure, undiluted performance. They bought their high-teehnology experienee to bear first on engines whieh were sold on to а number of manufacturers as original equipment. Both two- and four-stroke units were made, а 58 се and 148 се ОНС unit.
• One of the customer companies was Meihatsu Heavy lndustries, another company within the Kawasaki group, which in 1961 was shaken up and renamed Kawasaki Auto Sales. At the same time, the Akashi factory which was to Ье Kawasaki’s main production facility until the КоЬе earthquake of 1995, was opened. Shortly afterwards, Kawasaki took over the ailing Meguro company, Japan’s oldest motorcycle maker, thus instantly oЫaining а range of Ьigger Ьikes whieh were marketed as Kawasaki-Meguros.
• The following year, the first Ьike to Ье made and sold as а Kawasaki was produced, а 125 се single called the В8 and in 1963 а motocross version, the В8М appeared. The origins of the company, and its name, go baek to 1878 when Shozo Kawasaki set up а dockyard in Tokyo. Ву the late 1930s, the company was making its own steel in massive steelworks and manufacturing railway locos and rolling stock. ln the run up to war, the Kawasaki Aircraft Company was set up in 1937 and it was this arm of the now giant operation that would look to motorcycle engine manufacture in post-war Japan

TABLE OF CONTENTS:

Kawasaki ZR550 & 750 Zephyr Service Manual – PDF DOWNLOAD

lntroduction
Kawasaki – The Green Meanies Page 0•4
Acknowledgements Page 0•7
About this manual Page 0•7
Safety first! Page 0•8
ldentification numbers Page 0•9
Buying spare parts Page 0•9
Daily (pre-ride) checks
Engine/transmission oil level Page 0•10
Suspension, steering and drive chain Page 0•10
Brake fluid levels Page 0•11
Legal and safety checks Page 0•11
Tyres Page 0•12
MAINTENANCE
Routine mai ntenance and servicing
Specifications Page 1•1
Recommended lubricants and fluids Page 1•2
Maintenance schedule – ZR550 В & ZR750 С models Page 1•4
Maintenance schedule – ZR750 D model Page 1•5
Component locations Page 1•6
Maintenance procedures Page 1•7
REPAIRS AND OVERHAUL
Engine, transmission and associated systems
Engine, clutch and transmission Page 2•1
Fuel and exhaust systems Page 3•1
lgnition system Page 4•1
Chassis components
Frame, suspension and final drive Page 5•1
Brakes Page 6•1
Wheels Page 6•15
Tyres Page 6•23
Bodywork Page 7•1
Electrical system Page 8•1
Wiring diagrams Page 8•31
REFERENCE
Dimensions and Weights Page REF•1
Tools and Workshop Tips Page REF•2
Conversion Factors Page REF•20
Motorcycle Chemicals and Lubricants Page REF•21
МОТ Test Checks Page REF•22
Storage Page REF•27
Fault Finding Page REF•30
Fault Finding Equipment Page REF•39
Technical Terms Explained Page REF•43
lndex Page REF•47

Questions? Email us: [email protected]

IMAGES PREVIEW OF THE MANUAL:

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealers inorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

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