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KAWASAKI ZX400-H2 Quick Reference Manual Page 2

Quick reference guide (part 3).
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OTurn the
spring
preload adjuster fully counterclockwise
until the adjuster stops.
o
Screw in the rebound damp
ing
adjuster on the top bolt
so that the
distance
between the adjuster bottom and
the spring prelaod adjuster end is 25
mm.
12-10 SUSPENSION
Assembly
• Replace the bottom Allen bolt gasket with new one.
• Replace the following w
ith
new ones whenever they
have removed from inner
tube.
Oil
Seal
Dust Seal
.Visually inspect the
following,
and replace them if
necessary.
Guide Bush
a
-ring
of the Top Bolt
• Remove the guide bush from the inner tube and cover
the groove with vinyl for installing new dust seal and
oil seal.
• Install the follow
ing
onto the inner tube.
Dust Seal
Oil Seal
(spring
force upward)
Guide
Bush (outer tube
side)
.Install the
following
into the outer tube,
using
the oil
seal driver (special tool).
Guide Bush (outer tube side)
Washer
Oil Seal
A. 12 mm or more
B.
Rod Nut
C.
Piston Rod
1.
Fork
Oil
Seal
Driver:
57001 -1288
2
.
Oil Seal
.Applya non-permanent locking agent to the Allen bolt,
and tighten it to the
specified
torque (see Exploded
View)
.
• Insert the push rod in the piston rod.
.Pour
in the
specified
type and amount of o
il
(see Fork
Oil Change).
• Tighten the fork top bolt.
OTighten
the rod nut finger
-t ight.
o
Check that the visible thread length is at least 12 mm.
A. 25 mm
o
Install the
main
spring onto the push rod so that the
closed side is
upward.
o
Install the top spring and collar onto the push rod.
o
Press the top spring down with drivers, and insert the
fork spring stopper (special tool) between the piston
rod and the top spring
.
OTighten the top bolt
finger-tight.
o
While holding the fork top bolt, tighten the rod nut to
the specif
ied
torque (see Exploded View)
.
NOTE
ODo not remove the fork spring stopper (special tool),
while pressing the top spring down so that the spring
cause the force against the rod
nut.
o
Install the top
bolt
in the oute
r
tube.

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