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KAWASAKI ZX400-H2 Quick Reference Manual

Quick reference guide (part 2).
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6-4 ENGINE LUBRICATION SYSTEM
Engine Oil Flow Chart

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Table of Contents

   Summary of Contents for KAWASAKI ZX400-H2

  • Page 1 6-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart...
  • Page 2 ENGINE LUBRICATION SYSTEM 6-5 1. Oil Pump Filter 2. Oil Pump 3. Oil Filter 4. Oil Passage 5. Oil Pressure Switch 6. Releif Valve 7. Oil Hose 8. Camshaft Bracket 9. Camshaft 10. Rocker Arm 11. Oil Return Passage 12. Oil Pipe (to Mission) 13.
  • Page 3 (rpm). temp. °C (194°F) 216 - 275 kPa (2.2 - 2.8 kg/em ', 31 - 40 psi) Sealant Special Tools Kawasaki Bond (Silicone Sealant): 56019-120 Oil Pressure Gauge, kg/em'; 57001 -164 Oil Pressure Gauge Adapter, M18 x 1.5: 57001 -1278...
  • Page 4 ENGINE LUBRICATION SYSTEM 6-7 Engine Oil Change Engine Oil and Oil Filter .Support the motorcycle perpendicular to the ground after warming up the engine. • Remove the engine drain plug to drain the oil. AWARNING Motorcycle operation with insufficient. deter iorat or conta minated engine oi...
  • Page 5 6-8 ENGINE LUBRICATION SYSTEM OTighten the filter with the filter wrench to the Oil Pan specified torque (see Exploded View) or tighten it with hands about turns after gasket contacts the mounting surface of engine. 'Removal Pour in the specified type and amount of oil. .Set the motorcycleon its side stand.
  • Page 6 ENGINE LUBRICATION SYSTEM 6-9 Relief Valve, Oil Pump Filter Oil Pump Removal Removal • Remove the pan. • Remove the following Clutch (see Clutch chapter) • Unscrew the oil pressure relief valve from the engine. .Pull out the oil pump filter and the oil pipe. Circlip Oil Pump Gear Oil Pump Cover...
  • Page 7 6-10 ENGINE LUBRICATION SYSTEM Oil Hose Oil Cooler Removal Removal • Drain the engine oil. • Remove the following. • Remove the lower fairing (see Frame chapter). Engine Oil (Drain see this chapter) • Remove the Allen bolts from the cylinder head and the Lower Fairings (see Framechapter) crankcase.
  • Page 8 Oil Pressure Measurement Oil Pressure Measurement NOTE Measure the oil pressure after the engioe is warmed • Remove the following. Right Lower Fairing (see Frame chapter) Oil Passage Plug .Attach the oil pressure gauge and adapter (special tools) to the plug hole Pressure Gauge: 57001 -164 B.
  • Page 9: Table Of Contents

    ENGINE REMOVAL / INSTALLATION 7-1 Engine Removal/Installation Table of Contents Exploded View Special Tool Engine Removal/Installation Removal Installation...
  • Page 10: 7-2 Engine Removal / Installation

    7-2 ENGINE REMOVAL / INSTALLATION Exploded View (3.1 22 ft-Ib) kg-m. Install a shim ickness 0.5 mm) between the lower part 27 ft-Ib) of the crankcase and the frame bracket.
  • Page 11: Special Tool

    ENGINE REMOVAL / INSTALLATION 7-3 Special Tool Engine Removal/Installation Jack: 57001 -1238 Removal • Remove the following. Fairings (see Frame chapter) Engine Oil (Drain, see Engine Lubrication System chapter) Coolant (Drain, see Cooling System chapter) Fuel Tank (see Fuel System chapter) Air Cleaner Housing (see Fuel System chapter) Carburetors (see Fuel System chapter) Baffle Plate...
  • Page 12: Installation

    7-4 ENGINE REMOVAL / INSTALLATION Drive Chain (see Final Drive chapter) .FiII the engine w engine (see Engine Lubrication System chapter) • Fill the engine with coolant and bleed the air from the cooling system (see Cooling System chapter) . •...
  • Page 13 CRANKSHAFT / TRANSMISSION 8-1 Crankshaft I Transmission Table of Contents ...8-2 Exploded View Specifications ...8-4 ...8 Special Tools ...8-6 Sealant ...8-7 Crankcase Crankcase Splitting ...8 Crankcase Assembly ...8-7 ...8-9 Crankshaft/Connecting Rods Crankshaft Removal ..8 ..8-9 Crankshaft Installation .8-10 Connecting Rod Removal Connecting Rod Installation ..8-10...
  • Page 14: Exploded View

    27 N-m (2.8 kq-rn, 20 ft-Ib) G : Apply grease. ® Apply high temperature grease Apply l iquid gasket - black (Kawasaki Bond: 92104-1003) to the mating surface of the right and left crankcase halves. Apply a non-permanent locking agent to the threads. SS: Apply...
  • Page 15 RA N S M !SS O N 8··3 CRAN K...
  • Page 16: Specifications

    8-4 CRANKSHAFT / TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods: Connecting side clearance 0.13 - 0.38 0.60 mm Connecting rod end bearing insert/crankpin clearance 0.10mm 0.031 0.059 Crankpin diameter: 29.984 - 30 .000 29.97 - -- Marking None 29.984 - 29.994 29.995...
  • Page 17 CRANKSHAFT / TRANSMISSION 8-5 Item Standard Service Lim Crankshaft main bearing insert selectio Crankcase Main Crankshaft Main Bearing Insert" Bearing Bore Journal Diameter Size Color Diameter Mark Mark Part Number Jouma Nos. Brown 92028 -1418 92028 -1421 1,2,3,4 None Black 92028-1417 None 92028...
  • Page 18: Special Tools

    8-6 CRANKSHAFT / TRANSMISSION Special Tools Sealant KawaSll Socket Wrench. Hex 57001 -1268 Bond (Silicone Sealant): -120 Outside Circlip Pliers: 57001-144 92104-002 Bearinq Driver Set: 57001 -1129...
  • Page 19: Crankcase

    CRANKSHAFT / TRANSMISSION 8-7 .Apply a non -permanent lock agent to the plate Crankcase mounting bolt (see Exploded View) Crankcase Splitting • Remove the engine (see Engine Removal/Installation chapter) . • Set the engine on a clean surface and hold the engine steady while parts are being removed .
  • Page 20 Silver (Kawasaki Bond: 92014 -002) <1>6 x L40 mm A. <1>8 x L95 mm Silicone Sealant (Kawasaki Bond: 56019-120) B. <1>8 x L90 mm Apply silicone sealant upon liquid gasket. CAUTION If liqu gasket and silicone sealant adheres to any areas not indicated.
  • Page 21: Crankshaft/connecting Rods

    CRANKSHAFT / TRANSMISSION 8-9 Upper Crankcase Crankshaft/Connecting Rods Crankshaft Removal eRemove the engine. e Remove the cylinder head. cylinder and pistons. eSplit the crankcase (see Crankcase Splitting). eTake the crankshaft out of the upper crankcase. Crankshaft Installation CAUTION If the c ran k shaft bearing in se...
  • Page 22: Connecting Rod Removal

    8-10 CRANKSHAFT / TRANSMISSION Connecting Rod Removal • Remove the crankshaft. • Remove the connecting rods from the crankshaft. NOTE Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.
  • Page 23 CRANKSHAFT / TRANSMISSION 8-11 Connecting Rod Big End Bearing Insert/Crankpin Clearance 0.031 0.059 Standard: 0.10 Service limit: * If clearance is within the standard, no bearing replace- ment is required. 0.059 *If clearance is between mm and the service limit (0.10 rnrn), replace the bearing inserts with inserts painted blue.
  • Page 24: Crankshaft Main Bearing/journal Wear

    8-12 CRANKSHAFT / TRANSMISSION *If clearance exceeds the service limit, measure the diameter of the crankshaft main journal. Crankshaft Main Journal Diameter Standard: 29.984 - 30.000 mm Service Limit: 29.96 mm *If any journal has worn past the service limit, replace the crankshaft with a new one.
  • Page 25: Crankshaft Side Clearance

    CRANKSHAFT / TRANSMISSION 8-13 .Select the proper bearing insert in accordance with the comb ination of the crankcase and crankshaft coding. \llL Bearing In Size Color Mark Crankcase 3. No.2 Journal • Install the new inserts in the crankcase halves and check 2.
  • Page 26: Transmission

    8-14 CRANKSHAFT / TRANSMISSION Transmission Shift Pedal Removal • Remove the left lower fairing (see Frame chapter) • Mark the position of the shift lever on the shift shaft so that it can be installed later in the same position. •...
  • Page 27: Transmission Shaft Installation

    CRANKSHAFT / TRANSMISSION 8-15 View AA Transmission Shaft Installation .Be careful of the following. OApply eng oil to the sliding portion of the gears and bearings. Check to see that the set pins and set rings are in place. Install the drive shaft and output shaft into the upper crankcase half.
  • Page 28 8-16 CRANKSHAFT / TRANSMISSION ® 25.5 11.2..
  • Page 29: Shift Drum And Fork Removal

    CRANKSHAFT / TRANSMISSION 8-17 Shift Drum and Fork Removal Shift Drum Disassembly • Remove the following. .Remove the shift drum (see this chapter) Lower Crankcase Half (see Crankcase Splitting) • While holding the shift drum with a vise, remove the External Shift Mechanism (see this chapter) shift drum cam bolt.
  • Page 30 WHEELS / TIRES 9-1 Wheels I Tires Table of Contents Exploded View .. 9-2 Specifications . 9-3 Special Tools . 9-4 Wheels (Rims) Front Wheel Removal Front Wheel Installation . 9-5 . 9-6 Rear Wheel Removal ..9-6 Rear Wheel Installati on ..9-6 Wheel Inspection...
  • Page 31 9-2 WHE ELS / TIRES Exploded V::-·; ; - - - - - - - _ _ _ -lew grea~e.kg-m, T1· 11 N-m (11 0 G : Apply 80 ft-Ib)
  • Page 32: Specifications

    WHEELS / TIRES Specifications Item Standard Service Limit Wheels: runout (wi th tire installed) 0.5mm Radial 0.8mm Axle runout/1 00 mm Under 0.05 0.2mm Tires: pressu re (w hen cold Front 225 kPa (2.25 kq/ crn", psi) Rear 250 kPa (2.50 crn", psi) Tread...
  • Page 33: Special Tools

    9-4 WHEELS / TIRES Special Tools Bearing Driver Set: 57001 -1129 Bearing Remover Head. CIl15 x CIl17 57001 -1267 Jack: 57001 -1238 Bearing Remover Head. CIl20 x CIl22: 57001 -1293 Bead Breaker Assembly; 5700 -1072 Inside Circlip Pliers: 57001 -143 Protector: 57001 -1063...
  • Page 34: Wheels (rims)

    WHEELS / TIRES 9-5 Wheels (Rims) Front Wheel Removal • Remove the following. Lower Fairings (see Frame chapter) Speedometer Cable Lower End Right and Left Brake Calipers A. Jack or Stand B. Jack: 57001 -1238 .Pull out the axle to the right and drop the front wheel out of the forks.
  • Page 35: Rear Wheel Removal

    9-6 WHEELS / TIRES A. Rear Wheel B. Rear Calipe Bracket Housing Stop Front Fork Leg Stop CAUTION Fit the collar in the right side of the hub. Do not lay the wheel on the ground with the disc facing down This can damage or warp the disc.
  • Page 36: Balance Weight Installation

    WHEELS / TIRES 9-7 Rim Runout Check that the blade and weight seat fully on the rim flange, and that the clip is hooked over the rim ridge and reaches rim flat portion. AWARNING If the balance weight has any play on the rim flange. the blade and/or clip have been stretched.
  • Page 37: Balance Weight Removal

    9-8 WHEELS / TIRES Balance Weight Removal Tires (a) When the tire is not on the rim. • Push the blade portion toward the outs with a regular tip screw driver. and slip the weight off the rim Tire Air Pressure Inspection flange.
  • Page 38: Installation

    WHEELS / TIRES 9-9 1. Chalk Mark or Yellow Mark Valve Stem .Lubricate the tire beads and rim flanges on both sides a soap and water solution or rubber lubricant. This helps the tire beads slip off the rim flanges. Plastic Cap Valve Stem CAUTION...
  • Page 39 9-10 WHEELS / TIRES eAfter the tire beads seat in the rim flanges, check for air leaks. Inflate the tire slightly above standard inflation. Use a soap and water solution or submerge the tire, and check for bubbles that would indicate leakage. •...
  • Page 40: Hub Bearings

    WHEELS / TIRES 9-11 Speedometer Gear Housing Hub Bearings Disassembly and Assembly Removal • Remove the following. Wheel (see this chapter) NOTE Seals and Circlips It is recommended that the assembly be replaced rather .Use the bearing remover (special tool) to remove the than attempting to repair the components.
  • Page 41 FINAL DRIVE 10-1 Final Drive Table of Contents Exploded View .10-2 .10-3 Specifications .10-3 Special Tools .10-4 Drive Chain .10-4 Drive Chain Slack Adjustmen .10-4 Wheel Alignment Adjustment. Drive Chain Wear Inspection .10-4 .10-5 Lubrication .10-5 Drive Chain Removal Drive Chain Installation .10-6 .10-6...
  • Page 42 10-2 FIN Al DRIVE V-;·~------­ - - - Exploded _ _ _ ~f1 ew one bolt only <...
  • Page 43 FINAL DRIVE 10-3 Specifications Item Standard Service Limit Drive Ch ain : Make and type ENUM A EK520 - SX Endless links Chain slack 20 - 35 mm (3 5mm Less th 20 mrn. more than 40 mm 20-link length 318 .2 Special Tools Jack: 57001 -1238...
  • Page 44: Drive Chain

    10-4 FINAL DRIVE Drive Chain Drive Chain Slack Adjustment .Set the motorcycle up on its side stand and check that the chain slack is within the standard value. Drive Chain Slack 20 - 35 mm Standard: (35mm is best) Service Limit: 20 - 40mm Locknut C.Axle...
  • Page 45: Lubrication

    FINAL DRIVE 10-5 0___ " Oil Applied Areas ~~®~I Drive Chain Removal 21st • Remove the following. Lower Fairings (see Frame chapter) 1. Weight Ruler Chain Cover Straight Part Measure this length. Engine Sprocket Cover (see this chapter) Rear Shock Absorber Mounting Nut (lower) Drive Chain 20-link Length Tie-Rod Nuts (upper) Standard:...
  • Page 46: Drive Chain Installation

    10-6 FI NAL DRIVE Sprocket, Coupling Engine Sprocket Removal .Loosen the drive chain (see Drive Chain Slack Adjust ment) • Remove the following. Left Lower Fairing (see Frame chapter) Shift Pedal Engine Sprocket Cover Drive Chain Installation .Installation is the reverse of removal. Note the follow- ing .
  • Page 47: Rear Sprocket Removal

    FINAL DRIVE 10-7 Rear Sprocket Removal NOTE eRemove the rear wheel (see Wheels/Tires chapter) OSprocket wear is exaggerated for illustration. Sprocket Teeth CAUTION Do not lay the wheel on the grou n d with h e disc Worn Tooth Worn Tooth facing down This can damage or w a rp...
  • Page 48 BRAKES 11-1 Brakes Table of Contents Exploded View ..11 ..11-4 Specifications Special Tools ..11-4 ..11-5 Brake Fluid ..11- 5 Fluid Level Inspection ..11-5 Brake Fluid Change Brake Fluid Requirement: ..11-5 ..11-5 Changing Brake Fluid ..11-6 Bleeding the Brake Line ,..11-7 Brake Pedal Brake Pedal Position Adjustment ...11-7...
  • Page 49: Exploded View

    11-2 BRAKES Exploded View ® )o---~ (0.10 kg-m, 9 in-Ib) 1.2 N -m (0.12 10 in-Ib) 2.9 N-m (0.30 kg-m, 26 in-Ib) T4: 5.9 N-m (0.6 kg-m, 52 in-Ib) T5: 7.8 N (0.8 kg-m, 69 in-Ib) T6: 18 N-m (1.8 kg-m, 13.0 ft -Ib) T7: 21 N-m (2.1 kg-m, 15.0 ft-Ib) T8: 23 N-m (2.3 kg-m, 16.5 ft-Ib)
  • Page 50 BRAKES 11-3 G : Apply grease. M : Apply molybdenum disulfide grease.
  • Page 51: Specifications

    11-4 BRAKES Specifications Item Standard Service Limit Brake Fluid: Grade D.0.T.3 - -- Brand (recommended) Atlas Extra Heavy Duty Shell Super Heavy Duty Texaco Super Heavy Duty Wagner Lockheed Heavy Duty CastroI Girling - Universal CastroI GT (LMA) CastroI Disc Brake Fluid - -- Brake Lever Free...
  • Page 52: Fluid Level Inspection

    BRAKES 11-5 Brake Fluid Requirement: Brake Fluid Recommended fluids are given in the table below. If none of the recommended brake fluids are available. use extra heavy-duty brake fluid only from a container marked Fluid Level Inspection D.O.T.3. In accordance with the Period ic intenance Chart,...
  • Page 53: Bleeding The Brake Line

    11-6 BRAKES Bleeding the Brake Line Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action. Air, however, is easily compressed.
  • Page 54: Brake Pedal

    BRAKES 11-7 Brake Pedal Brake Pedal Position Adjustment • Check that the brake pedal is in the correct position. Pedal Position Standard: About 43 mm below from center of brake pedal shaft Hold the brake applied 2. Quickly open and close the valve.
  • Page 55: Rear Brake Light Switch Adjustment

    11-8 BRAKES Rear Brake Light Switch Adjustment Calipers .Check the operation of the rear brake light switch by depressing the brake pedal. The brake light should go on after about 10 of pedal travel. Front Caliper Removal • Remove the following. Banjo Bolt (at the caliper) Caliper Mounting Bolts CAUTION...
  • Page 56: Front Caliper Disassembly

    BRAKES 11-9 A. Banjo Bolt Caliper Mounting Bolts A. Caliper Assembly Bolts Caliper Assembly Bolts • Remove the piston insulator and the O-rings. • Using compressed air, remove the pistons. One way to remove the pistons is as follows. Caliper Installation Install a wooden board more than 10 mm thick and a rubber gasket on the caliper half as shown Leave one...
  • Page 57: Rear Caliper Disassembly

    11-10 BRAKES AWARNING To avoid serious mjurv, never place your fingers or palm inside the caliper opening. If you apply compressed air n t o the caliper. the piston may crush your hand or fingers Pull out the pistons by hand.
  • Page 58: Brake Pads

    BRAKES 11-11 Brake Pads Front Brake Pad Removal • Remove the following. Spring Clip Pad Pin A. Piston Insulators B. O-Rings .Tighten the caliper assembly bolts to the specified torque (see Exploded View) A. Pad Spring Clip A. Pad Pin •...
  • Page 59: Installation Notes

    11-12 BRAKES Lining Wear • For front caliper pad inspection, remove the pad spring (see Front Caliper Removal) • For rear caliper pad inspection, remove the rear caliper (see this chapter) • Remove the pad cover. *If the lining thickness of either pad is less than the service limit.
  • Page 60: Master Cylinders

    BRAKES 11-13 Rear Master Cylinder Installation Notes Master Cylinders • Use a new flat washer on each side of the brake hose fitting. • Tighten the banjo bolts to the specified torque (see Front Master Cylinder Installation Exploded View) . •...
  • Page 61: Assembly

    11-14 BRAKES Assembly Brake Discs • Before assembly, clean all parts includ the master cylinder with brake fluid or alcohol. .Apply brake fluid to the removed parts and to the inner Installation wall of the cylinder. .Install the brake disc on the wheel so that the rotation mark aligns w the tire rotation.
  • Page 62 BRAKES 11-15 1. Brake Disc Turn the wheel by hand. Disc Runout Standard: Under Service limit:...
  • Page 63 SUSPENSION 12-1 Suspension Table of Contents ...12·2 Exploded View ...12-4 Specifications ...12-5 Special Tools ...12 Front Fork ...12-6 Rebound Damping Force Adjustment ..12-6 Spring Preload Adjustment ...12-6 Fork Oil Change ...12-8 Removal ...12-8 Installation ...12-8 Disassembly .12-10 Assembly .12-11 Rear Shock Absorber .12-11 Rebound Damping Force Adjustment .
  • Page 64 12-2 SUSPENSION Exploded View 15 N-m (1 -m.11 ft-Ib) 20 N kg-m. 14.5 ft-Ib) T3: 23 N-m (2 kg-m. 16 ft-Ib) T4: 39 N-m (4 kq-rn, 29 ft-Ib) T5: 49 N-m (5.0 kq-rn, 36 ft-Ib) T6: 88 N-m (9.0 kq-rn, 65 ft-Ib) T7: 110 N 80 ft-Ib) Apply molybdenum disulfide...
  • Page 66 12-4 SUSPENSION Specifications Item Standard Service Limit Front Fork: Rebound damping setting 6th click from fully counterclockwise posit Spring preload setting 1/4 turn out position from fully counterclockwise position Fork oil: Viscosity SAE5W Amount (perside): when chang 355 mL After disassembly and completely dry 421 ±4 mL Oil level (fully compressed,...
  • Page 67 SUSPENSION 12-5 Special Tools Steering Stem Nut Wrench: 57001 -1100 Oil Syringe: 57001 -1290 Bearing Driver Set: 57001 -1129 Fork Cylinder Holder: 57001 -1297 Fork Piston 57001 · Fork Outer Tube Weight: 57001 -1218 Puller, Jack: 57001 -1238 Fork S .11 Driver: 5700 •...
  • Page 68 12-6 SUSPENSION Front Fork Rebound Damping Force Adjustment eTo adjust the rebound damping, turn the rebound damping adjuster until you feel a click. A. Preload Adjuster OThe standard adjuster setting for the average-build rider of 68 kg (150 Ib) with no passenger and no accessories mm as shown.
  • Page 69 SUSPENSION 12-7 Fork Oil Change NOTE • Remove the following. Measure the fork oil level compressing the outer tube Front Fork (see Front Fork Removal) and piston rod down with the push rod installed. Top Bolt Top Spring Main Spring OSet the oil syringe stopper so that its lower...
  • Page 70 12-8 SUSPENSION Removal • Remove the following. Lower Fairing Front Wheel Front Fender Mounting Bolts and Screws Fork Clamp Bolts (uppe and lower, loosen) Handle Holder Clamp Bolts (loosen) A. Outer Tube Steering Stem Head .Tighten the following fasteners to the specified torque (see Exploded View).

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