kawasaki zx 600, zx 750 Service Manual
'".
HAYNES
SERVICE
&
REPAIR
MANUAL
(GPZ600R.
GPH600R.
nlDJa
600R
&
ZH750
(GPH750R. ninja
750R)
'85
to
'97
"Haynes Manuals just cannot
be
beaten"
M:Jlor
C\'CIe
News
-
--
-------
COLOUR
wiring
diagrams
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•
Kawasaki
ZX600
&
750
Fours
Service and Repair Manual
by Bob Henderson
and John H Haynes
Member of the Guild of Motoring Writers
Models
covered
ZX600A (GPZ600R). 592cc. UK 1985 through 1990
ZX600A (Ninja 600R). 592cc. US 1985 through 1987
ZX600B alumininum frame model (Ninja 600RX). 592cc. US 1987
ZX600C (GPX600R). 592cc.
UK
1988 through 1996
ZX600C (Ninja 600R). 592cc. US 1988 through 1997
ZX750F (GPX750A). 748cc. UK 1987 through 1991
ZX750F (Ninja 7S0R). 748cc. US 1987 through 1990
C H
ayne.
Pubtlahlng 1999
A book
In
lhe
Hayne.
Service and Repair Manual
Serl"
PrInted in the USA
Haynes Publishing
Sparkford, Yeovil, Somerset 8A22 7 JJ, England
Hayn
es Nort
h America, Inc
(178()-.260-3Y3)
All
lights
,..
..
rHd.
No
part
of
this
book
may
be
reproduced
or
trans
mitted
In any
lorm
or
by
any
means,
electronic
or
machanical,
including
photoeopyil'lg,
rKOrding
or
by
any
information
ItOf'lllil8
or
rwtrieval system,
withotlt
pennl,lIon
In
writing
from
tIw
eopyright
holder.
861
Lawrence
Drive,
Newbury Park, California 91320, USA
ISBN 1
85980
230 4
Libllory
01
CongrHl
Catalog
Card
Numt:.r
81.12743
British Ubrary Cataloguing In
Pub~cation
o.ta
A catalogue record lor this book is
a~ailabkllrom
the Bntl$h Ubrary.
Edit
ions
Haynes
4, Rue
de
l'Abreuvoir
92415 COURBEVOIE CEDEX, France
Hayn
es
Publishing Nordiska
AS
Box 1504,
751
45
UPPSAlA,
Sweden
All manuals and user guides at all-guides.com
Contents
LIVING WITH YOUR KAWASAKI
Introduction
Kawasaki - The Green Meanies
Page
0·'
Acknowledgements
Page
0·7
About this manual
Page
0·7
Safety first!
Page
0·8
Identification numbers
Page
0·.
Buying spare parts
Page
0·9
Daily (pre-ride) checks
Engine/transmission oil level
Page
0-10
Clutch fluid level (750 models)
Page
0-10
Brake fluid levels
Page
0-11
Suspension, steering and drive chain
Page
0-11
Coolant level
Page
0-12
Legal and safety checks
Page
0-12
Tyres
Page
0-13
MAINTENANCE
Routine maintenance and servicing
Specifications
Page
'·2
Recommended lubricants and fluids
Page
'·3
Component locations
Page
,.,
Maintenance schedule
Page
,
..
Maintenance procedures
Page
'·7
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REPAIRS AND OVERHAUL
Engine, transmission and associated systems
Engine,
clutch
and transmission
(BOO
models)
Engine,
clutch
and transmission (750 models)
Cooling
system
Fuel and exhaust systems
Ignition system
Chassis components
Frame, suspension and final
drive
Brakes
Wheels
Tyres
Fairing
and
bodywork
Electrical system
Wiring diagrams
REFERENCE
Dimensions and Weights
Tools and Workshop Tips
Conversion
Factors
Motorcycle Chemicals and Lubricants
MOT Test Checks
Storage
Fault Finding
Fault Finding Equipment
Technical
Terms
Explained
Index
Contents
Page
2A.'
Page
28-1
Page
3·,
Page
4·'
Page
5·'
Page
6·'
Page
7·'
Page
7-10
Page
7-13
Page
8·,
Page
9·,
Page
9·20
Page
REF·1
Page
REF-2
Page
REF-20
Page
REF-21
Page REF·22
Page REF·26
Page REF-28
Page
REF-36
Page REF·40
Page REF-44
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REF-44 Index
Note: Referern;es throughout this index relata to Chapter-page number
A
About
this
Manual·
0-7
Acknowledgements·
0-7
Air
fiher·
'-15,
4-11
Air
suction
valves -
,-a
Alternator -'-20,
28-25,
9-16,
9-17
Anti·dive
seals -'-23
Anti-dive
valve
assembly
-
6-9
Antifreeze -0-12,
'-2,
'-20,
,-21
Asbestos -
o-a
B
Battery·
o-a,
'-16,9-2,9-3
Bearings·
REF·14
Bleeding
brakes -
7-10
clutch -
28-19
Brake fluid - 0-11,
'*2,
'*23
Brakes, wheels
and
tyres
-
'*12,
7-'
ot seq,
REF·24
bleeding -7-10
brake fiuid - 0-11,
'*2,
'-23
caliper -
'-23,
7-2
disc(s) - 7-S
hoses and lines
-'-24,
7-9
lever -
9-7
light -'*13, 9-5,
9-7
master cylinder - 7-6,
7-7
pads-,·,2,7-3
pedal-I-13,
g-a
plunger unit -
6-9
tyres
-7-13
wheel bearings -
7-12
wheels -
7-10
wheels alignment
check
- 7-11
Break-in
procedure
-
28-30
Brushes
and
slip
rings -9-18
c
Cables -
1-18
, 2A-26, 4-10, 4-11
Caliper
- 1-23,
7-2
Camshafts
- 2A-8, 2A-9, 2A-35,
28-6, 28-7,
28-25
Carburenor
- 1-22, 4-3,
4-4,
4-5,
4-8
synchronisation -
1-9
Centrestand -6-3
Chain -
0-11,
1-7,
1-12,
6-16,
REF-18
Charging -9-3,
9-15
Chemicals
- REF-21
Choke
cable
- 4-11
Clutch
(600 models) - 1-11, 2A-23
cables - 2A-26
Clutch
(750 models) - 2S-15,
28-18
clutch fluid -
0-10,1-2,1-23
bleeding
-2S-19
hoses -
1-24
master cylinder -
28-18
slave cylinder -
28-18
Clutch
fluid
- 0-10,
1-2,
1-23
Coils
- 5-3,
5-4
Connecting
rods
- 2A-29, 2A-31 ,
28-22
,
28-23
Conversion
factors
- REF-20
Coolant·
0-12,1-2
Coolant
pump -3-9
Coolant
reservoir -3-5
Coolant
temperature
gauge -3-6
Cooling
fan -3-5
Cooling
system
- 1-20, 1-21, 3-1
et
seq
coolant pump -
3-9
coolant res9I'Voir -
3-5
coolant temperature gauge -
3-6
fan -
3-5
011
cooler -
3-10
radiator -
3-8
radiator
cap -3-5
switch -
3-5
temperature gauge -
3-6
thermostat -
3-7
thermostat housing -
3-7
thermostatic fan -
3-5
water
pump -3-9
Crankcase
- 2A-27, 2A-28,
28-20,
28-22
Crankshaft
- 2A-29,
28-23
Cylinder
block
- 2A-17, 28-11
Cylinder
compression -1-24
Cylinder
head
- 2A-13, 2A-15,
28-9,
28-11
D
Daily (pre-ride)
checks -0-10
et
seq
Dimensions -REF-l
Dlrectlon
Indicator
assemblies -
9-7
bulbs -
9-6
Disc(s) -
7-5
Drive beH -
1-20
Drive
chain
-1-7,
0-11, 1-12, 6-16, REF-18
E
Electric
Suspension
Control
System
(ESCS) -
6-10
Electrical
system
- 9-1
et
seq,
REF-22
alternator-g-16,
9-17
battery - 9-2,
9-3
brake lever -g-7
brake light -
9-5
brake light switches -
9-7
brake pedal -
9-8
brushes -
9-18
charging - 9-3,
9-15
direction indicators- 9-6,
9-7
fault finding -
9-2
fuel gauge -
9-8
fuses -
9-3
gauges -
g-a
handlebar switches - 9-1 0
headlight - 9-5,
9-6
horn -
9-12
ignition main
(key)
switch -
9-10
indicators - 9-6, 9_7
instruments -
g-g
junction box -
9-3
licence plate light -
9-5
lighting system -
9-5
meters -
g-a
neutral indicator light -
9-5
neutral switch -
9-10
numberplate light -
9-5
oil pressure sending unit -
g-g
oil pressure warning light -
9-5
pedal -
g-a
regulator/rectifier -
9-17
sidestand switch - 9-12
slip
rings -
9-18
speedometer -
g-g
starter motor -
9-13
starte!' solenoid - 9-12
stop light - 9-5,
9-7
switches - 9-7, 9-10, 9-12
tachometer -
g-g
taillight - 9-5,
9-7
temperature gauge -
g-g
tum signal assemblies - 9-6,
9-7
voltage regulatorlrectifier - g-17
warning light bulbs -
g-g
wiring diagrams -
9-19
et
seq
Electricity -o-a
Electrolyte -
'-16
•
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Engi
ne
1600
models)
camshaft - lA-
a,
lA
-g, 2A-
35
connecting rods - 2A*29, 2A-
31
crankcase -
2A
*27, 2A*28
crankshaft -2A*29
cylinder block - 2A· 17
cylinder head - 2A* 13, 2A*15
main
bearings -
2A
. 29
oil pan -2A-
21
oil pressure relief valve -2A*23
011
pump - 2A-
22
Piston rings - 2A-20
pistons - 2A*18
removal
and
installation - 2A. 4
rocker
arms
- 2A· 12
starter
motor
-
2A
*34
sump - 2A-
21
valve cover -ZA-?
valves - 2A* 14, 2A-IS
Engin
e (750
models)
alternator -28-25
break-In procedure
-26*
30
camshaft -28-
6,
2S-
7, 28-25
connecting rods -2S-22, 2S*23
crankcase
-28*20, 28-22
crankshaft
-
28
-23
cylinder block - 2B- l1
cylinder
head
-
28-9,
2B-
l1
main bearings -
28*22, 28*
23
oil pan -28*12
011
pressure relief valve -28- 14
011
pump
-
2a*13
piston rings -
28
-12
pistons -
28
-12
removal and installation -28*4
rocker arms - 2B. 7
running-In procedure -28*
30
starter -
28
*25, 2S*23, 2S.
24
sump -
28
-12
valve
cover
-
2S
-6
valves -
28
· "
Engine fautt
finding
- S. 2
Engine
oil - 1.
2,
0
.'
0,
1· 14
Engine
, c
lut
ch
and
transmission
(600
model
s) - 2A
.l
at
seq
Englna, clutch
and
transmis
sion
(750modfl/s)
- 2
8.1
at
seq
EvaporativfI flmission
controi
system
-'·
'0
Exhaust system
- ' .
'7, 4.'3,
REF· 23
F
Fairing
and
bodyworlc - a
-I
et
seq
fairing - 8-8
fairing stays - a- g
fendS!"
- 8-
9,
8. 10
knee grip
COVefS
- a. g
mudguard - 8-
9,
8· 10
seat -8·
'0
side
COVefS
- 8 -9
tailpiecfl - 8-10
windshlflld -
8. 9
Fan
- 3-S
Fasteners-I-
17, REf-S
Fault
finding
- REF-28
fit
seq
electricai systfIITI - 9-2
flngine - S-2
Fflnder-a-g, a-l
0
Filter
ai
r -I-IS, 4-
11
luel-I
-19
oil-I
-14
Final
drive -REF
-23
Footpegs
- 6-3
ForlI;
oil-
' -2, ' .
21
Forks
- 6. 4
Frame,
suspension
and
I/na/
drive-
6. 1
at
seq
anti-dive valve assembly - 6-9
brake plunger unit - 6-9
centrestand - 6-3
chain - 6
-'
6
Electr
iC
Suspension Control Systam (Escs)
- 6-10
footpegs - 6-3
forKs - 6· 4
frame - 6-
2,
6· 3
handlebars
- 6· 3
rocker
ann
- 6
·'
2
rubber
damper
- e- 17
shock absorber - 6-
12
side stand - 6-3
sprockets - 6
.'
6
steering head bearings - 6· 10
suspension linkage - e-12
swingarm - e-
IS
tia-rod - 6- 12
uni-trak - 6-
12
wheel coupling - 6- 17
Fuel and
exhaust
systems-
' ·
'9,4·'atseq
air fin
er-4
· "
cable - 4·
1,
cables
-4
-10
carburetlors - 4.
3,
4-4,
4-
5, 4-8
choke cab
la
- 4-
11
exhaust system -4-13
fil
ter-
I-1
9
fuel level adjustment -
4_
9
fuel level
S8flSOf
- g-g
fuel tank - 4-3
gauge - g-a
hoses
-'
· 23
Idle mixture adjustment - 4. 3
mixture adjustment
- 4- 3
thro
tt
le cables - 4- 10
throttle
grip·
4-1 0
Fumfls
- o·a
Fuses - 9· 3
G
Gaskets
- REF- 17
Gauges
-9
· 8
Gear
shift
mechanism
- 2A-26, 28·
'9
Gearbox
oil
- 0- 10,1- 2
Glossary -
REF
· 40
at
seq
Index REF
o
45
H
Ha
ndlebar.
- 6-3
switCh&$;
- 9-10
Headlight
- g- S
aim - 9-6,
REF-22
bulb - 9-5
Hom - 9-
12
Hoses
-'
-23, 1-
24,
7-
9,
REF-19
I
Ie
IgnHer - 5-S
Idle mi
xture adjustment
- 4-3
Idle s
peed
- ,-g
Ignition
system
- 5-' et seq
colis - 5-
3,
S- 4
fault finding - 5-2
Ie
Igniter - 5-S
main (key) switch - 9-1 0
misfire - 5-2
Indicat
ors
assemblies·9
-7
bulbs - g. e
Instruments
bulbs - 9-9
cluster - 9-8
J
Junction
box
- 9-3
K
Knee
grip
C
OYilf'S
- a·9
L
Legal chec
ks - 0.
,2
Ucence pla
te
light
- 9. 5
Ughtlng system
- 9-S
Lubrication
- 1-
13,
REF-21
M
Main
bearing
s -
2A
-29,
28
·22, 28-23
Maintenance sc
hedute -
1.
6
Ma
ster
cylinder -1.
23, 28-18, 7.
6,
7-7
Met.,..
- g- a
Misfir
e - 5-2
Mixture
adjustment
- 4- 3
MOT
test cheeks -
REF
-22
et
seq
brakes -
REF
-24
electrical system -
REF -22
exhaust -
REF -23
final drive -
REF
-23
headlight beam height -
REF
-22
sidecars
-
REF
. 25
steering -
REF
.23
suspension -
REF
. 23
tyres -
REF -24
wheels -
REF
-24
Mudguard
- a-g, a-
l0
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REFo46 Index
N
Neutral
indicator
light
- 905
Neutral
switch
- 9010
Numberplate
light -90S
o
Oilcooler-3010
Oilfitter-'·14
Oil
pan
-
2Ao21 , 28.12
all
pressure
relief
valve - 2Ao23,
28.14
all
pressure
sending unit - gog
warning light - 905
all
pump
- 2Ao22,
2S.13
Oil
seals
-'.23,
REF.16
Oil
engine/transmission -
0.'0,
'02,
,.14
fOrK-,02,
1021
p
Pads
,'.12,
703, goa
Pedals
-'.13
Pickup coils - 504
Piston rings - 2Ao20,
28.12
Pistons
- 2Ao18,
28.12
R
Radiator
- 308
cap - 305
Recommended
break-in
procedure
- 2Ao39, 28030
Reference
- REF-,
at
seq
Regulator/rectifier
- go17
Rocker
arms
- 2Ao12, 2S07
Routine maintenance and
servicing -
,.,
at seq
Rubber
damper
- 6017
Running-in
procedure
- 2Ao39, 2S030
s
Safety
first!
- ooa,
0.12
Sealants
- REFo17
Seals
-,023,
REF-16
Seat -a-lO
Shock
absorber -6-12
Side
covers -a-g
Sidestand -6-3
switch -
9-12
Sidecars
- REF-25
Slave
cylinder -2B-18
Spark
plugs -1-a,
'-20
Specific
gravity
- 1
-16
Speedometer -9-9
Sprockets
-1-12,
6-16
Starter
motor -2A-34,
28-23,
2S-24,
2S-25,
9-13
Starter
motor
clutch·
2A-33
Starter
solenoid·
9-12
Steering
- 0-11, REF-23
Steering
head -'-23
bearings - 1-15,
6-10
Stoplight -1-13,
9-5
switches -
9-7
Storage
- REF-26
Sump
- 2A-21 ,
2S-12
Suspension -0-11,
1-24, REF-23
Suspension
linkage
(Uni-Trak) - 6-12
Swing
arm -1-20,
6-15
Switches
-1-13,
3-5,
9-7,
9-1O,
9-'2
T
Tachometer -9-9
Taillight -9-5
bulbs -
9-7
Taitplece
- a-1 a
Technical
terms
explained
- REF-40
et
seq
Temperature
gauge -3-6,
g-g
Thermostat -3-7
housing -
3-7
Thermostatic
fan -
3-5
Throttle
cables -1-18,4-10
Throttle
grip -4-10
Tie-rod -6-12
Tools
snd
worlcshop
tips
- REF-2
at
seq
Torque
- REF-13
Transmission
(BOO
models)
gear shift mechanism -
2A-26
primary chain -
2A-35
secondary sprocket -
2A-33
shafts - 2A-35,
2A-36
Transmission
(750
models)
gear shift mechanism -
2S-1g
shafts - 2S-25,
2S-26
Transmission
oil-
a-la,
1-2
Transmission
shafts
- 2A-35,
2A-36
Tum
signal
assemblies -
g-7
bulbs -
9-6
Tyre
pressures
- 0-13,
1-2
Tyres - 0-13, 1-16, 7-13, REF-24
u
Unl-Trak -6-12
linkage -
1-20
v
Valves - 2A-14, 2A-15, 2S-11
clearances
-'-17
cover - 2A-7,
2S-6
Voltage
regulator/rectifier -9-17
w
Warning
light
bulbs -g-g
Water
pump -3-9
Weights
- REF-1
Wheels
·1-16,
7-10, REF-24
bearings
- 1-23,
7-12
coupling -
6-17
Wheels
alignment
check
-7-11
Windshield -8-9
Wiring
diagrams -g-1g
et
seq
Workshop
- REF-4
tips - REF-2
•
l
•
•
1
I
C
I
I
•
•
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•
Kawasaki
ZX600
&
750
Fours
Service and Repair Manual
by Bob Henderson
and John H Haynes
Member of the Guild of Motoring Writers
Models
covered
ZX600A (GPZ600R). 592cc. UK 1985 through 1990
ZX600A (Ninja 600R). 592cc. US 1985 through 1987
ZX600B alumininum frame model (Ninja 600RX). 592cc. US 1987
ZX600C (GPX600R). 592cc.
UK
1988 through 1996
ZX600C (Ninja 600R). 592cc. US 1988 through 1997
ZX750F (GPX750A). 748cc. UK 1987 through 1991
ZX750F (Ninja 7S0R). 748cc. US 1987 through 1990
C H
ayne.
Pubtlahlng 1999
A book
In
lhe
Hayne.
Service and Repair Manual
Serl"
PrInted in the USA
Haynes Publishing
Sparkford, Yeovil, Somerset 8A22 7 JJ, England
Hayn
es Nort
h America, Inc
(178()-.260-3Y3)
All
lights
,..
..
rHd.
No
part
of
this
book
may
be
reproduced
or
trans
mitted
In any
lorm
or
by
any
means,
electronic
or
machanical,
including
photoeopyil'lg,
rKOrding
or
by
any
information
ItOf'lllil8
or
rwtrieval system,
withotlt
pennl,lIon
In
writing
from
tIw
eopyright
holder.
861
Lawrence
Drive,
Newbury Park, California 91320, USA
ISBN 1
85980
230 4
Libllory
01
CongrHl
Catalog
Card
Numt:.r
81.12743
British Ubrary Cataloguing In
Pub~cation
o.ta
A catalogue record lor this book is
a~ailabkllrom
the Bntl$h Ubrary.
Edit
ions
Haynes
4, Rue
de
l'Abreuvoir
92415 COURBEVOIE CEDEX, France
Hayn
es
Publishing Nordiska
AS
Box 1504,
751
45
UPPSAlA,
Sweden
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Contents
LIVING WITH YOUR KAWASAKI
Introduction
Kawasaki - The Green Meanies
Page
0·'
Acknowledgements
Page
0·7
About this manual
Page
0·7
Safety first!
Page
0·8
Identification numbers
Page
0·.
Buying spare parts
Page
0·9
Daily (pre-ride) checks
Engine/transmission oil level
Page
0-10
Clutch fluid level (750 models)
Page
0-10
Brake fluid levels
Page
0-11
Suspension, steering and drive chain
Page
0-11
Coolant level
Page
0-12
Legal and safety checks
Page
0-12
Tyres
Page
0-13
MAINTENANCE
Routine maintenance and servicing
Specifications
Page
'·2
Recommended lubricants and fluids
Page
'·3
Component locations
Page
,.,
Maintenance schedule
Page
,
..
Maintenance procedures
Page
'·7
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