1976–1979 Kawasaki KZ750 Service Manual (P/N 99997-744-04)

• Factory coverage for the 1976–1979 Kawasaki KZ750 B-series twin, with 1979 B4 coverage limited to non-US models.
• Engine removal and installation, crankcase separation, camshaft-chain fitting, and balancer timing procedures support internal engine repair.
• Mikuni BS38 dual-carburetor service covers fuel-level adjustment, vacuum-piston inspection, and synchronization with or without vacuum gauges.
• Drivetrain sections address wet multi-plate clutch service, Hy-Vo primary-chain wear, five-speed transmission disassembly, and kickstarter service.
• Front and rear disc-brake repair includes pad replacement, caliper and master-cylinder overhaul, fluid changes, and bleeding.
• Model-specific wiring diagrams support ignition, charging, starter, and lighting fault tracing for US, Canadian, and European configurations.

Model Coverage and Factory Revisions

This 236-page PDF reproduces Kawasaki Heavy Industries, Ltd.’s Motorcycle Service Manual, Part No. 99997-744-04, Revised 5, August 30, 1989. It covers the 745cc DOHC air-cooled twin, not the four-cylinder KZ750.

The application chart lists beginning frame numbers KZ750B-000001 for the 1976 KZ750-B1 and KZ750B-016101 for the 1977 KZ750-B2. Later entries are KZ750-B-025701 for the 1978 KZ750-B3 and KZ750B-033101 for the 1979 KZ750-B4. The original 1976 service sections are accompanied by a supplement for subsequent design changes.

Engine Overhaul and Fuel-System Service

Core sections document the cylinder head, valve train, and piston assemblies. Engine repair extends to compression testing, valve-seat refacing, valve-guide inspection, and cylinder boring. Crankshaft and connecting-rod sections cover bearing-clearance checks and color-coded rod-bearing insert selection. The Valve Adjustment Chart and Valve Installed Height Procedure Table support shim selection and checks after valve work.

Lubrication coverage includes oil-pressure testing, trochoid oil-pump inspection, and an Engine Oil Flow Chart. Relief-valve service distinguishes the piston-type design from the ball-type unit introduced during 1977 production.

Fuel-system explanations trace the starter, pilot, main, and float circuits rather than stopping at carburetor removal. The manual warns that a pinched carburetor diaphragm can be damaged and prevent the vacuum piston from returning freely.

Transmission inspection covers gear dogs, shift forks, shafts, and bearings. The 1978-and-later output-shaft procedure addresses the three-ball neutral locator, with an Output Shaft Gears sectional view showing the assembly.

Brake, Suspension, and Wheel Service

Revised front-brake procedures account for the caliper position and master-cylinder changes introduced for 1978. The supplement’s service-limit table distinguishes single-disc and optional dual-disc front master cylinders.

Chassis procedures cover front-fork disassembly and seal replacement, steering-stem bearings, wheel runout, and spokes. Final-drive chain and sprocket inspection addresses wear and alignment.

Swing-arm service separates 1976–1977 bushings from 1978-and-later needle bearings. Rear shock absorbers are covered as sealed units for inspection and replacement, not internal rebuilding.

Ignition and Charging-System Diagnosis

The 1976–1977 charging sections test the three-phase, field-coil dynamo and separate regulator and rectifier. The 1978-and-later supplement covers the single-phase permanent-magnet dynamo and combined regulator/rectifier, with output, resistance, and short-circuit checks.

Contact-breaker ignition coverage includes dwell, timing-advance, capacitor, and coil tests. Starter diagnostics address the relay, brushes, armature, and starter clutch; the model-application chart identifies the starter lockout switch added for 1977. The Z750-B4 Wiring Diagram (European Model) includes ignition- and handlebar-switch connection tables.

Engine and Chassis Specifications

Factory tables provide component-specific torque and locking-agent requirements, fluid capacities, wear limits, and clearance specifications. Electrical test values accompany the relevant checks. Engine and running-performance curves are also included. Symptom-based troubleshooting covers starting difficulty, poor running, shifting problems, abnormal noise, and handling faults.

The Flow Chart for Disassembly identifies removal dependencies and operations requiring special tools. The tool list names valve lifter holder 57001-501, rotor holder 57001-255 for 1976–1977, and flywheel holder 57001-308 for 1978 and later models.

Always refer to the factory handling precautions and safety warnings outlined in these sections before attempting any mechanical work to ensure safe operation.