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KAWASAKI ZX400-H2 Quick Reference Manual

Quick reference guide (part 3).
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C. Piston Rod Nut
Push Rod
Piston Rod Nut
.Pour the fork oil into a container.
• Remove the following from the outer tube.
Dust Seal
A. Push Rod
B. Piston Rod
Inner Tube
57001 -1218
3. Outer Tube
4. Pull
• Use the fork outer tube weight (special tool) to separate
the inner tube from the outer
the inner tube by hand in a vertical
pull down the outer tube several
to pull out the
inner tube
OThe oil seal, washer, and guide bushes come off with
the inner
• Hold the axle holder in a
• Stop the cylinder from tuming by
the front fork
cylinder holder (special too
• Unscrew the Allen bolt, then take the bolt and gasket
out of the bottom of the axle holder
4. Allen Wrench
Axle Holder
1. Cylinder Holder: 57001 -1297
2. Piston Cylinder
3. Allen Bolt
A. Dust Seal
hold the outer tube at d
Or the
in de r
unit co
u ld
the b
o ttom Allen
bo lt
n n ot
be r


Table of Contents

   Summary of Contents for KAWASAKI ZX400-H2

  • Page 1 SUSPENSION 12-9 Push Rod Piston Rod Nut --t- A. Push Rod C. Piston Rod Nut B. Piston Rod .Pour the fork oil into a container. • Remove the following from the outer tube. Dust Seal Circlip Inner Tube 3. Outer Tube ight: 57001 -1218 4.
  • Page 2 12-10 SUSPENSION Assembly • Replace the bottom Allen bolt gasket with new one. • Replace the following w new ones whenever they have removed from inner tube. Seal Dust Seal .Visually inspect the following, and replace them if necessary. Guide Bush -ring of the Top Bolt •...
  • Page 3 SUSPENSION 12-11 Rear Shock Absorber Rebound Damping Force Adjustment The rebound damping force adjuster at the lower end of the rear shock absorber has 4 positions so that the rebound damping force can be adjusted for different road and loading conditions.
  • Page 4 12-12 SUSPENSION Banjo Bolt A. Rear Shock Absorber Mounting Bolt, Nut (upper) Scrapping AWARNING Since the rear shock absorber conta nitrogen gas. do not incinerate the rear shock absorber w ithout first releasing the gas or it may explode. Before a rea r shock absorber is scrapped.
  • Page 5 SUSPENSION 12-13 Swing Arm Sleeve Inspection Swing Arm If there is visible damage, replace the sleeve, the ball bearing, and all the needle bearings as a set. Removal • Remove the following. Rear Wheel (see Wheels/Tires chapter) Shock Absorber Mounting Bolt (lower) Tie-Rod Bolts (upper) Swing Arm Shaft A.
  • Page 6 12-14 SUSPENSION Tie-Rod, Rocker Arm Tie-RodRemoval • Remove the following. Lower Fairings (see Frame chapter) Rocker Arm (see Rear Shock Removal) Lower and Upper Tie-Rod Bolts A. Rocker Arm Grease Nipples Rocker Arm Removal .The rocker arm is removed dur the rear shock removal.
  • Page 7 SUSPENSION 12-15 Tie-Rod Rocker Arm Sleeve Inspection there is visible damage, replace the sleeve and needle bearing(s) as a set.
  • Page 8: Table Of Contents

    STEERING 13-1 Steering Table of Contents ..13-2 Exploded View ...13-3 Special Tools ...13-4 Steering Adjustment ...13-4 ...13-5 Steering Stem Removal ...13-5 ...13-5 Installation ..13-7 Steering Stem Bearing Bearing Lubr ication ...13-7 Bearing Wear, Damage ...13-7 ...13-7 Stem Cap Deterioration, Damage.
  • Page 9: Exploded View

    13-2 STEERING Exploded View 9.8 N (1.0 kq -rn, 7.0 ft-Ib) T2: 23 N (2.3 kg -m. 16.5 -Ib) T3: 39 N .0 kg-m. 29 ft-Ib) 25 N -rn, 19.0 ft-Ib) grease. Apply...
  • Page 10: Special Tools

    STEERING 13-3 Special Tools Stem Bearing Driver: 57001 -137 Head Pipe Outer Race Driver: 57001 -1106 Stem Bearing Driver Ad apter: 5700 1· 1092 Steering Stem Nut Wrench: 57001 -1100 Head Pipe Outer Race Remover: 57001 -1107 Bearing Puller: 57001 -1 Bearing Puller Adapter: 57001 -317...
  • Page 11: 13-4 Steering

    13-4 STEERING Steering Stem Head Nut Steering Front Fork Lower Clamp Bolts .Check the steering' again. * If the steering is still too tight or too loose, repeat the Adjustment adjustment. .Check the steering. Lift the front wheel off the ground using the jack (special tool: 57001...
  • Page 12: Steering Stem

    STEERING 13-5 Steeri n9 Stem Removal • Remove the following parts. Surge Tank (see Fuel System chapter) Upper and Lower Fairings (see Frame chapter) Front Fork Legs (see Suspension chapter) Brake Hose Joint Steering Stem Head Stem Head, Handlebar, Handle Holder •...
  • Page 13 13-6 STEERING .1 GreaseSeal Apply grease to the lower tapered roller bearing, and drive it onto the steering stem using the stem bearing 1. Upper Bearing 4. Stem Locknut 57001-137 driver and adapter (special tools: 2. O-ring 5. Pawl Washer 57001 -1092).
  • Page 14: Steering Stem Bearing

    STEERING 13-7 Choke Cables Steering Stem Bearing Clutch Front Brake Bearing Lubrication • Perform the following Remove the steering stem Using a high-flash point solvent, wash the upper and lower tapered roller bearings in the cages. Wipe the upper and lower outer races, which are press-fitted into the frame head pipe, clean of grease...
  • Page 15 FRAME 14-1 Frame Table of Contents .14 -2 Exploded View .14-5 Seats .14-5 Front Seat Removal .14-5 Front Seat Installation . .14-5 Rear Seat Removal .14-5 Rear Seat Installation . .14-6 Side Covers .14-6 Side Cover Removal .14-6 Fairings .14-6 Upper Fairing Removal.
  • Page 16 14-2 FRAME Exploded View ducts rem ve th OUl, pawl from II c insid fuel rank. Apply a non-permanent locking agent to the threads.
  • Page 17 FRAME...
  • Page 18 ® -:t:(' 1<9 pply Qrcase Apply no In g threads...
  • Page 19: Seats

    FRAME 14-5 Seats Front Seat Removal • Remove the front seat mounting bolt. move it upward and slide it forward. A. Seat Lock B. Seat Mounting Belt Rear Seat Installation • Install the seat mounting belt. .Slip the hooks of the rear seat under the brace on the frame and put the stoppers of the seat into the holes in A.
  • Page 20: Side Covers

    14-6 FRAME Side Covers Fairings Upper Fairing Removal Side Cover Removal • Remove the following. • Remove the following in the order listed. Front Seat Rear View Mirror Nuts Rear Seat Upper Fairing Mounting Bolts and Screws Seat Pad Air Duct Clamps (Loosen) Left and Right Cover Clamp Screws Turn Signal Connectors Side Cover Mounting Screws...
  • Page 21 FRAME 14-7 NOTE ORemove the lower fairings as assembly.
  • Page 22 ELECTRICAL SYSTEM 15-1 Electrical System Table of Contents Precaut ions ...15-2 Brush Inspection .15 -21 iring Diagram (ZX400-H2) ...15-3 Commutator Cleaning Inspection .15- 21 Parts Location ...15-4 Armature Inspection .15- 22 Exploded View ...15-5 Brush Lead Inspection Specification s .........•..
  • Page 23 15-2 ELECTRICAL SYSTEM Color Codes: Precautions Black Blue Brown There are a number of important precaut ions that are Chocolate musts when servicing electrical systems. Learn and Dark green observe all the rules below. Green Do not reverse the battery lead connections.
  • Page 24 ELECTRICAL SYSTEM 15-3 Wiring Diagram (ZX400-H2)
  • Page 25 15-4 ELECTRICAL SYSTEM Parts Location Headlight Unit Meter Unit 3. Starter Motor Tail/Brake Light 5. Licence Light Fan Switch Alternator Oil Pressure Switch Neutral Switch Side Stand Sw itch 11. Turn Signal Light Fuel Pump Water Temperature Sensor Radiator Fan Rear Brake Light Switch Pickup Coil Indicator Light...
  • Page 26 ELECTRICAL SYSTEM 15-5 Exploded View N-m (0 kq-rn, 56 in-Ib) N-m (0.85 kg-m. 74 in-Ib) T3: 8.8 N-m (0.90 kg-m. 78 in-Ib) kq-rn. 13 N-m (1 113 in-Ib) 25 N-m (2 kq-rn, 18 ft-Ib) T6: 34 N -rn, 25 ft-Ib) 78 N-m (8 58 ft-Ib) ' "...
  • Page 27 ...."'; ,::- " < (irl "'~ "...
  • Page 28 " " " ...::: " ;:::'I" -' 1 1;- - - :.8 N (0.9 greasekg-m. in - Ib )
  • Page 29 15-8 ELECTRICAL SYSTEM Specifications Item Standard Service Limit Battery: - -- Type 12V10Ah Specific gravity 1.280 @20"C "F) Alternator: - -- Charging voltage 14.5 V Night @4 000 r/rn in (rpm) - - - Output voltage No less than 43 V @4 000 r/m in (rpm) Stator coil resistance...
  • Page 30 Special Tools Hand Tester: 57001-983 Flywheel Holder: 57001 -1313 Coil Tester: 57001 -1242 57001 · 1216 Spark Plug Wrench, Hex 16: 57001 -1262 Hotor Puller, 5700 Socket Wrench, Hex 57001 -1268 Sealant Kawasaki Bond (Silicone Sealant): 56019-120 Jack: 57001 -1238...
  • Page 31: Inspection

    15-10 ELECTRICAL SYSTEM *If the specific gravity is below 1.20 (charge 60%), Battery battery needs to be charged. Electrolyte LevelInspection .The electrolyte level should be between the upper and Initial Charging the lower level lines. .Remove the rear and front seats (see Frame chapter) * If the level of electrolyte in any cell is below the lower and take out the battery.
  • Page 32 ELECTRICAL SYSTEM 15-11 Charging System Keep the battery away from sparks and open f la mes dul"ing charging, since the battery gives off an Alternator Cover Removal explosive g mixture of hydrogen and oxygen. W he n • Remove the lower fairing. using a battery charger, connect the b atte ry .Set a suitable container under the...
  • Page 33 15-12 ELECTRICAL SYSTEM A. Silicone Sealant Applied Area A. Flywheel Holder: 57001 -1 31 3 C. Rotor Bolt B. Rotor .Apply silicone sealant to the left inner cover bolt. .Threads the rotor puller (special tool) and the rotor puller (special tool) onto the alternator rotor . •...
  • Page 34 ELECTRICAL SYSTEM 15-13 Alternator Rotor Cleaning Area A. Holding Plate Mounting Bolts Grommets Stator 1. The tapered portion of the crankshaft. The alternator rotor bolt and the threads in the crankshaft. 3. The tapered portion of the alternator rotor Stator Installation Notes 4.
  • Page 35 15-14 ELECTRICAL SYSTEM Connect the hand tester (special tool: 57001 -983) Rectifier Inspection as shown in table. • Check the rectifier resistance as follows. Note the readings (total 3 measurement) .Remove the regulator/rectifier and disconnect the connector 2 (see Charging System Wir Diagram).
  • Page 36 ELECTRICAL SYSTEM 15-15 .Connect the brown lead terminal to the other battery terminal and connect the black/yellow lead terminal to the battery ( -) terminal momentarily. At this time the bulb should not be lit. W Lead Terminal 4. Y, Lead Terminal BR Lead Terminal 5.
  • Page 37 15-16 ELECTRICAL SYSTEM e Repeat the above three steps for other two yellow leads Ignition System (in connector 2 which leads to the regulator/rectifier». * Replace the regulator/rectifier if the bulb does not light as described above. A WARNING NOTE Th e ig nitio n system prod uces extremely...
  • Page 38 Set the meter to the x 1 kO, and read the meter. * If the meter does not read as specified, replace the coil. NOTE OSince a tester other than the Kawasaki coil tester may Ignition Coil Winding Resistance produce a different arcing distance, the Kawasaki coil Primary Windings: 2.3 - 3.50...
  • Page 39 15-18 ELECTRICAL SYSTEM .Check the spark plug leads for visible damage. *If any spark plug lead is damaged, replace the coil. Ignition System Wiring Diagram 'J.!' ,It' BKIY Bl< ..l > > :>: 16. Diodes 8. Ignition Coil 1. IC Igniter (#2, #3 Cylinder) 17.
  • Page 40: Cleaning And Inspection

    CAUTION Spark Plug Installation Note Use only Hand Tester 57001 -983 for this test. A tester .Tighten the spark plugs to the specified torque other than the Kawasaki Hand Tester may show (see Exploded View). ifferent readings. • Run the spark plug leads correctly (see Cable Routing...
  • Page 41 15-20 ELECTRICAL SYSTEM IC Igniter Internal Resistance Range: kO Electric Starter System Starter Motor Removal • Remove the fuel tank (see Fuel System chapter). ester Positi ve Lead Co nnection • Remove the terminal nut of starter motor wiring and take Ter- minal out the mounting bolts.
  • Page 42 ELECTRICAL SYSTEM 15-21 Starter Motor Assembly Note • Inspect the O-rings if it is not damaged • Install the brushes and springs into the end cover holder. Clamp the brush leads w clips on the end cover and springs. NOTE OBe careful not to damage the leads and O-rings.
  • Page 43: Armature Inspection

    15-22 ELECTRICAL SYSTEM Segment 2. Shaft 1. Commutator Emery Cloth NOTE • Measure the diameter of the commutator. OEven if the foregoing checks show the armature to be Replace the starter motor with a new one if the good. it may be defective in some manner not readily commutator diameter is less than the service limit.
  • Page 44 ELECTRICAL SYSTEM 15-23 Brush Plate and Terminal Bolt Inspection .Using the x 1 ohmmeter range, measure the resist- ance as shown between terminal bolt and brush plate between terminal bolt and (-) brush between terminal bolt and end cover If there is any reading, the brush holder assembly and/or terminal bolt assembly have a short.
  • Page 45 ELECT RICA L Electric Starter and Fue Pump Circu it "-------- - - >18 ...--H ~---- ----- : d:6 [!1]...
  • Page 46: Beam Horizontal Adjustment

    ELECTRICAL SYSTEM 15-25 Lighting System headlight beam is adjustable both horizontally and vertically Headlight aiming must be correctly adjusted both for your safety as well as that of oncom drivers. In most areas it is illegal to ride w an improper adjusted headlight.
  • Page 47: Headlight Unit Removal/installation Note

    15-26 ELECTRICAL SYSTEM Good A. Pin Closest to Base. 1. Dust Cover 2. Headlight Bulb • Insert the socket by aligning the tangs with the catches .Check the headlight aim after installation. in the housing so that the triangular mark points left, and turn it clockwise.
  • Page 48: Radiator Fan System

    ELECTRICAL SYSTEM 15-27 Radiator Fan System Fan System Circuit Inspection • Remove the left lower fairing and disconnect the leads from the radiator fan sw itch. Tum Signal Relay .Check the cond ition or the relay for the following troubles. (1) Neither right nor left turn signals come on at all:...
  • Page 49: Fan Inspection

    15-28 ELECTRICAL SYSTEM Headlight Circuit Headl ight Junction 80 R/BK-- --..1 High Beam Indicator / y -- -..J Dimmer witch Fan Inspection Fan Installation • Remove the following .Tighten the fan mounting bolt to the specified toruqe Surge Tank (see Exploded View in the Cool System chapter)
  • Page 50: Removal/installation

    If the tester readings are normal, check the fuel pump operation. CAUTION Use only Hand Tester 57001-983 for this test. ohmmeter other than the Kawasaki Hand Tester may show different readings. If a megger or a meter with a large-capacity battery is used.
  • Page 51 15-30 ELECTRICAL SYSTEM Fuel Pump Relay Internal Resistance .Connect the pump leads to the battery using auxiliary ires as shown *If the pump operates, check the pump relay. *If the pump does not operate, the pump is defective. Tester Connection *If the pump operates and the pump relay is normal.
  • Page 52: Replacement

    ELECTRICAL SYSTEM 15-31 Meters, Gauges Removal • Remove the following. Upper Fairing (see Frame chapter) Headlight Unit Speedometer Cable Upper End Wiring Connectors • Remove the meter unit by taking off the mounting nuts. A. Pull the bulb. Meter, Gauge Assembly Note •...
  • Page 53: Temperature Gauge Operation Inspection

    15-32 ELECTRICAL SYSTEM CAUTION Do not ground the wiring longer than necessary. After the pointer swings to the H position. stop th test. Otherwise the gauge could be damaged If these readings are not correct. the trouble is w gauge and/or iring.
  • Page 54 ELECTRICAL SYSTEM 15-33 Tachometer Circuit - - - - - - - - - - - - - ..----; --r-, ,..- - BK-- - ® 1. Ignition Switch 6. Ignition Coil (#1 2. 6-Pin Connector Spark Plug Tachometer 30A Main Fuse in Starter Relay Battery 4-Pin Connector IC Igniter...
  • Page 55: Temperature Sensor Inspection

    15-34 ELECTRICAL SYSTEM Water Temperature Sensor Inspection Fan Switch Resistance .Suspend the sensor in a conta iner of coolant so that the Rising temperature: temperature sensing projection and th readed portion are From OFF to ON at 93-103° C submerged. (199-217°F) •...
  • Page 56: Fuse Removal

    ELECTRICAL SYSTEM 15-35 Fuse Inspection Junction Box • Remove the fuse (see Fuse Removal). • Inspect the fuse element. * If it is blown out. replace the fuse. Before replacing a The junction box has fuses, relays, and diodes. The blown fuse, always check the amperage in the affected...
  • Page 57: Diode Circuit Inspection

    15-36 ELECTRICAL SYSTEM Starter Circuit • Remove the junction box (see Fuse Removal) • Check conductivity of the following numbered terminal by connecting the hand tester (special tool) and one 12 V battery to the junction box as shown. *If the relay does not work as specified, replace the junction box.
  • Page 58: Wiring Inspection

    ELECTRICAL SYSTEM 15-37 Junction Box Internal Circuit <t <{ >- ' " " ::.> .?E' '" "U "0 "1 '" @@@0 0 000@ @G)O@@ O·Pin Connec 8·Pin Connect Electrical Wiring Wiring Inspection .Visually inspect the wiring for signs of burning, fraying, etc.

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