1. 1976 Kawasaki Kz750 Parts

The first Kawasaki KZ750 twin was built in 1975 and sold as a 1976 model as a KZ750B1. For the first four years of production (1976-79), the KZ750B1 through B4 shared identical Mikuni BS38 carburetor assemblies. These assemblies are probably the heaviest twin-carb assemblies ever built and have a couple unique features.

The biggest oddity is that the Kawasaki version of the BS38 uses a system where both the pilot jet and main jet are screwed into the float bowl. A good bowl gasket is critical because gas is drawn from the jets into the internal passages that lead to the venturi via channels beneath the gasket inside the float chamber.

The pilot jets used are standard BS series fare in that they are Mikuni BS30/96 type but the main jets are unique to Kawasaki BS38 carburetor assemblies. They look like very small air jets and are frequently stripped as they require the correct sized small screwdriver to remove.

Complete official full factory download kawasaki kz750 h2 z750 h2 1981. Kawasaki kz750 z750 kz z 750 workshop service repair manual 1976 1979 here.

Installation To prevent accidental vehicle start-up, which could cause death or serious injury, remove maxi-fuse before proceeding. (00251a) 1 WARNING 1 WARNING ® Kit Numbers 41279-04, 41282-04, 41463-05, 41467-05, 41633-05, 41634-05, 41640-05, and 41639-05 1 of 3 Figure 1. Rear Wheel Removal i02495 1. Axle (keep) 2. Axle adjuster (keep) 3. Axle nut (keep) 4.

“E”-clip (keep) 5. Spacer (3) (keep) 6. Torx screw (5) (replace) 7. Brake disc (keep) 8.

Wheel assembly (replace) 9. Valve cap (keep) 10. Compensator bowl (keep) 11. Compensator cushion (keep) 12.12 pt screw (5) (keep) 13. Lockwasher (5) (keep) 14. Sprocket assembly (keep) 1. Refer to the Service Manual and follow the MAXI-FUSE instructions to remove the right-side cover and maxi- fuse.

Proceed to Step 2 for the wheel being replaced. Rear Wheel 2. See Figure 1. Remove the rear wheel per the REAR WHEEL, REMOVAL instructions in the Service Manual.

Disassemble, clean and inspect all parts to be re-used per Service Manual instructions. Re-assemble all saved components to the new chrome rear wheel assembly.

1976 Kawasaki Kz750 Parts

See REAR WHEEL, ASSEMBLY in the Service Manual. Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Fasten the brake disc to the valve stem side of the wheel using the Torx®screws from the kit. Install the compensator bowl with the 12-point screws and lockwashers saved earlier.

Install the new wheel to the rear fork. Refer to REAR WHEEL, INSTALLATION in the Service Manual. Proceed to Step 7. Front Wheel 2. See Figure 2. Remove the front wheel per the FRONT WHEEL, REMOVAL instructions in the Service Manual. Disassemble, clean and inspect all parts to be re-used per Service Manual instructions.

Mark the left and right brake discs so they can be re-installed to the same location. Re-assemble all saved components to the new chrome front wheel assembly. See FRONT WHEEL, ASSEMBLY in the Service Manual.

Do not re-use brake disc screws. Re-using disc screws can result in torque loss and damage to rotor and/or brake assembly. Using the Torx ® shoulder bolts from the kit, and the saved spring washers fasten the brake discs to the same side of the wheel from which they were removed. Install the new wheel to the front forks per the FRONT WHEEL, INSTALLATION instructions in the Service Manual. Proceed to Step 7.

Front and Rear Wheels 7. Refer to the Service Manual and follow the MAXI-FUSE instructions to replace the maxi-fuse and right-side cover. After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a) After servicing the brake system, test brakes at low speed.

If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a) Maintenance and Cleaning Chrome parts must be maintained regularly to ensure that they keep their original shine and luster. Clean heavily-soiled wheel surfaces using Harley Wheel and Tire Cleaner, part number 94658-98, applied with Harley Wheel and Spoke Brush, part number 43078-99. Thoroughly clean chrome with a good quality chrome cleaner, such as Harley Bright Chrome Cleaner, part number 94683-99. After cleaning and polishing, seal the finish with a good quality sealer such as Harley Glaze Polish and Sealant, part number 99701-84 Incoming search terms:. REMOVAL Prepare for Service 1. Position motorcycle on a suitable lift.

NOTE If vehicle is equipped with Harley-Davidson Smart Security System, see owner’s manual for instructions to disarm the system. To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. Disconnect battery cables, negative (-) battery cable first.

Remove seat according to the instructions in the service manual. Refer to service manual to remove left saddlebag and side cover.

Gm factory service manual. When servicing the fuel system, do not smoke or allow open flame or sparks in the vicinity. Gasoline is extremely flammable and highly explosive, which could result in death or serious injury. Remove fuel tank according to the instructions in the service manual. Remove Engine Components 1. Remove existing air cleaner assembly. Discard backplate but save remaining parts. Refer to AIR CLEANER REMOVAL in service manual.

Remove existing exhaust system. Refer to EXHAUST SYSTEM REMOVAL in service manual. Remove engine from chassis following the instructions in the service manual.

Disassemble engine top end and bottom end. Refer to appropriate ENGINE sections in service manual.

Remove existing clutch diaphragm spring. Refer to CLUTCH REMOVAL in service manual.

The procedures in this instruction sheet should be performed by one experienced in precision measuring techniques. Failure to meet tolerances called for in this instruction sheet can result in engine damage. (00511b) -J04793 1 2 is03517 1.

O-ring counterbore 2. Spigot bore Figure 1. Spigot Bore and O-Ring Counterbore Dimensions Table 1.

Spigot Bore and O-Ring Counterbore Dimensions Depth Bore Description 1.625 +/- 0.010 in. (41.3 +/- 0.25 mm) 4.205 +/- 0.010 in. (107 +/- 0.25 mm) Spigot Bore 0.085 +/- 0.003 in. (2.16 +/- 0.08 mm) 4.415 +/- 0.002 in. (112 +/- 0.05 mm) O-Ring Counter- bore is03456 Figure 2. Cylinder Wall MACHINE CRANKCASE Crankcase Boring Preparation NOTE During final assembly of the engine, Harley-Davidson recommends replacing the OE cylinder studs with Screamin’ Eagle High Tensile Studs (16505-01). Remove cylinder studs from the engine crankcase.

Mask off all bearings and oil holes to prevent debris and contaminants from entering those areas. Inspect and clean engine case mating surfaces. See Figure 6. Reassemble engine case with OE screws, except the top center screw between the cylinders, and tighten to specifications listed in service manual. NOTE To prevent damage to crankcase boring tool, it is important to replace the top center screw with a modified top center screw (1093). This screw is included in the Crankcase Boring Tool Kit (94419-06) and can be purchased separately from a Harley- Davidson dealer. Install modified top center screw (1093) between the cylinders and tighten to 50-90 in-lbs (5.6-10.2 Nm).

See Figure 1 and Table 1. Machine crankcase cylinder spigot bore and O-ring counterbore to the dimensions shown. Modify Crankcase Incoming search terms:. Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery.

(Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank. (Refer to Service Manual, Page 5-3) 3.

Remove the air cleaner box. (Refer to Service Manual, Page 5-14) 4. Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation. Install the air cleaner box in reverse order of removal. (Refer to Service Manual, Page 5-14) 6.

Lower the fuel tank. (Refer to Service Manual, Page 5-3) 7. Remove the upper seat rail plate. Disconnect and remove the ECM. (Figure 1) @ ISC Valve Mounting Screw Torque: 2.1± ±0.6 N.m (1.5± ±0.4 lb-ft)! Carefully insert the ISC valve straight into the throttle body hole to prevent damaging the o-ring.

Turn the ISC valve slightly to confirm that the o-ring has not twisted. Using the new screw provided in the replacement parts kit, make sure the screw is completely seated on the plate after the screw has been tightened to the specified torque.

Remove and replace the ISC valve. (Refer to Service Manual, Page 5-25) NOTE: Since the ECM is also being replaced there is no need to perform the ISC valve preset operation.! Cover the throttle bodies to prevent anything from dropping into the engine. Remove the front seat and disconnect the battery. (Refer to Service Manual, Page 8-8) 2. Lift up the fuel tank.

(Refer to Service Manual, Page 5-3) 3. Remove the air cleaner box. (Refer to Service Manual, Page 5-14) REPLACEMENT PROCEDURE: 8. Install the new ECM in reverse order of removal. Apply thread lock to the upper plate mounting bolts when reinstalling the upper seat rail plate.

Incoming search terms:. ENGINE REMOVAL: 1. Turn ignition off, remove lanyard, disconnect battery cables and remove battery. Remove engine following steps outlined in section 7 of Kawasaki service manual.

NOTE: Replace oil filter if engine was run previously. Please recycle used oil and oil filter. NOTE: Clear an area on a sturdy workbench or heavy-duty cart to place engine after removal. Be sure to carefully place engine on a smooth surface so as not to damage oil pan.

It is recommended that you have assistance for the engine removal process. Replace stock pistons, rings, piston pins, clips, cylinder head gasket and cylinder base gasket with supplied forged pistons, rings, piston pins, clips, cylinder head gasket and cylinder base gasket following the steps outlined in section 6 of the Kawasaki service manual. NOTE: This is an involved process requiring advanced mechanical skills and 4-stroke engine experience. DO NOT ATTEMPT if you are not mechanically inclined or familiar with 4-stroke engines. Remove OE crankshaft coupler and discard. Locate boss on PTO housing just above crankshaft.

Cut off at a 45° angle. (See page 1 of Installation Images) NOTE: Cover end of crankshaft. Thoroughly clean engine afterwards. EXHAUST SYSTEM MODIFICATIONS: 6. Inside hull under rear grab handle remove air inlet tubes.

Disconnect hoses for stock bilge pick-ups from breather fittings. (see illustration #1) 7. Remove exhaust hose connecting primary muffler (left water box) to secondary muffler (right water box). Disconnect remaining hoses from breather fittings. Remove exhaust hose connecting secondary water box to exhaust outlet. (see illustration #2) NOTE: Retain hose clamps. Remove section of foam between top deck and pump area and discard.

At rear of hull remove and discard plastic exhaust outlet nozzle. Remove exhaust outlet, cut 5-3/4″ from end of flange and weld a bead around modified end of exhaust outlet. (see illustration #3) NOTE: Sand or file edge after modifying. Install one supplied silicone coupler onto modified exhaust outlet and secure using OE hose clamp.

(see illustration #4) Install exhaust outlet into hull and secure using stock hardware. (see illustration #5) NOTE: Be sure rubber gasket is in place between flange and hull.

Do not use any sealant. Apply blue Loc-tite to bolts. Do not over tighten bolts. Install supplied billet exhaust outlet tip using supplied hardware. (see illustration #6) NOTE: Apply blue Loc-tite to bolts.

Do not over tighten bolts. Incoming search terms:. REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. Refer to the service manual and follow the instructions given to remove the main fuse. Remove the outer fairing. See the service manual. Remove the fairing cap.

See the service manual. FLHX Models: Handlebar-mounted mirrors (purchased separately) are required for proper installation of this handlebar. Removal of the inner fairing may be required, refer to the service manual. If fairing-mounted mirrors are being removed: Install the two small black plugs and large black plugs (purchased separately) to plug the fairing mirror holes. Direct contact of D.O.T. 4 brake fluid with eyes can cause irritation.

Avoid eye contact. In case of eye contact flush with large amounts of water and get medical attention.

Swallowing large amounts of D.O.T. 4 brake fluid can cause digestive discomfort. If swallowed, obtain medical attention. Use in well ventilated area. KEEP OUT OF REACH OF CHILDREN.

(00240a) D.O.T. 4 brake fluid will dama ge painted and bod y panel surfaces it comes in contact with.

Always use caution and protect surfaces from spills whenever brake work is performed. Failure to comply can result in cosmetic damage. (00239b) NOTE Immediately wipe up any brake fluid spillage with a clean, dry, soft cloth. Follow up by thoroughly wiping affected area with a clean, damp, soft cloth (small spills) or washing with a large quantity of soapy water (large spills). Cover nearby motorcycle surfaces with a polyethylene protective sheet to help protect against damage to finish caused by spillage or splashes of DOT 4 brake fluid.

Drain the brake fluid from the front brake reservoir and lines per the instructions in the service manual. NOTE Cover the front fender and the fuel tank with clean shop towels to prevent scratching. Models with Radio: Remove the radio. See the service manual. Models without Radio: Remove the storage box. See the service manual.

The four socket head screws fastening the radio or storage box to the left and right radio support brackets can be accessed through the oblong holes in the fairing brackets. Use a long shank ball-end socket to remove the screws. Pull the radio or storage box forward to remove it from the opening in the inner fairing. Remove brake line components carefully. Damage to seating surfaces can cause leakage.

Remove and retain the button head screw on the underside of the fork stem and bracket assembly that holds the brake line manifold tee. Note the front brake line routing and the orientation of the banjo fittings. Disconnect the brake line from the front brake calipers and the front brake master cylinder assembly. Save the banjo bolts, but discard the two gaskets found at each banjo fitting. See the service manual. Remove the front brake line assembly.

NOTES Refer to the parts catalog for this year and model for a replacement OE brake line assembly and clutch cable, if needed. Ask a Harley-Davidson dealer about the selection of Genuine Motor Accessory Custom Braided Clutch Cables and Brake Lines that are available. Remove the front brake master cylinder and clutch lever assemblies from the handlebar.

Disconnect the clutch cable from the clutch lever. See the service manual. Incoming search terms:.

Description This 237 page, 1976 1977 1978 1979 Kawasaki KZ750 B Factory Service Manual provides detailed service information, step-by-step repair instruction, maintenance specifications and wiring diagrams for 1976-1979 Kawasaki KZ750 B Twin cylinder motorcycles. This is a reproduction manual with a comb binding of the original Kawasaki Service Manual that is no longer produced. The first issue of this Kawasaki service manual was based on the 1976 Kawasaki KZ750.

Since the first issue, certain design changes have been made which require a new dis­assembly or maintenance procedure. These new procedures which can not be included in each section are explained in an included supplement. This Kawasaki KZ750 manual is designed primarily for use by motorcycle mechanics in a properly equipped shop, although it contains enough detail and basic information to make it useful to the Kawasaki KZ750 owner who wants to carry out his own basic maintenance and repair work. Since a certain basic knowledge of motorcycle mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily; the adjustments, maintenance, and repair should be carried out only by qualified mechanics whenever the owner has insufficient experience, or has doubts as to his ability to do the work, so that the motorcycle can be operated safely. In order to perform the work efficiently and to avoid costly mistakes, the mechanic should read the text, thoroughly familiarizing himself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment is specified, makeshift tools or equipment should not be used.

Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation of the motorcycle. Purchasing this manual and reading it will always allow you to follow safe operating and maintenance practices.