Kawasaki KZ750 B1–B4 Service Manual 1976–1979 (P/N 99997-744-04)

This reproduces Kawasaki Heavy Industries, Ltd.'s Motorcycle Service Manual, P/N 99997-744-04, Revised 5, August 30, 1989, for the 1976–1979 KZ750 B-series DOHC air-cooled twin. The integrated supplement covers later design changes; 1979 B4 coverage is limited to non-US models. It does not cover the four-cylinder KZ750.

PDF Text Search and Wiring-Diagram Viewing

Search and diagram viewing: PDF text search and embedded bookmarks are unavailable. Wiring diagrams are arranged sideways, and small connector labels and switch tables require zooming.

ZIP download containing one printable 236-page PDF. This total includes the 14-page supplement, two-page index, and six unnumbered cover, conversion, and safety pages.

Twin-Engine Repair and Model-Specific Service

The selected coverage below highlights major workshop tasks. Other documented topics include fuel-tap cleaning and horn adjustment.

• Engine repair: Step-by-step engine removal and installation, crankcase separation, camshaft-chain fitting, and balancer timing procedures.

• Fuel system: Mikuni BS38 dual-carburetor service covers fuel-level adjustment, vacuum-piston inspection, and synchronization with or without vacuum gauges.

• Drivetrain: Wet multi-plate clutch service, Hy-Vo primary-chain wear checks, transmission disassembly, and kickstarter service.

• Disc brakes: Front and rear pad replacement, caliper and master-cylinder overhaul, brake-fluid changes, and bleeding.

• Chassis: Front-fork disassembly, steering-stem bearing service, wheel and spoke inspection, and swing-arm service.

• Electrical diagnosis: Model-specific wiring diagrams and tests for ignition, charging, starter, and lighting faults on US, Canadian, and European configurations.

It is written primarily for motorcycle mechanics in a properly equipped shop, while owners need basic mechanical knowledge and qualified help for work beyond their experience.

Engine Overhaul and Lubrication

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. 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. The ball-type valve is inspected as an assembly and replaced if cleaning does not restore its operation.

Carburetor Circuits and Diaphragm Handling

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.

Crankshaft and Transmission Inspection

Crankshaft and connecting-rod sections cover bearing-clearance checks and color-coded rod-bearing insert selection. Clutch checks compare friction-plate wear, plate warp, and spring tension with factory limits.

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 inspection includes wheel runout and spoke condition, plus final-drive chain and sprocket 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. Front-fork procedures include seal replacement and model-specific oil and spring data.

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. These distinctions let you select the matching charging tests before investigating low output.

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.

Workshop Charts and Special Tools

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.

The periodic maintenance chart schedules routine service. 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 before mechanical work, especially when handling brake components or open fuel lines.

Valve-Clearance and Fuel-Level Examples

For valve-clearance checks, the manual gives a cold specification of 0.05–0.10 mm between the cam and shim.

For the Mikuni BS38 carburetors, the service fuel-level specification is 4.5–6.5 mm below the carburetor body's bottom edge. The measurement is taken at the carburetor center with the motorcycle upright.