Kawasaki KZ400 Service Manual

342

Table of Contents

- 4
  Quick Reference Guide
238
Appendix
- 239
  Additional Considerations for Racing
- 240
  To Inspect the Spark Plugs
- 240
  Spark Plug Reach
- 241
  Special Tools
- 245
  KZ500-B1 Wiring Diagram
- 246
  Supplement
- 247
  Supplement for 1980 Model
- 247
  Table of Contents
- 248
  Adjustment
  - 249
    KZ400-J1 (Left Side View)
  - 249
    KZ400-J1 (Right Side View)
  - 249
    Model Identification
  - 250
    Front Disc and Rear Drum Brake
  - 251
    Specifications
  - 253
    SPECIFICATIONS (On KZ550)
  - 255
    Engine Performance Curves (On KZ400)
  - 255
    KZ400-J1 (Except West German Model)
  - 256
    Engine Performance Curves (On KZ550)
  - 256
    KZ550-A1, C1 (US and Canadian Models)
  - 257
    Running Performance Curves (On KZ400)
    - 258
      Running Performance Curves (On KZ550)
  - 259
    Periodic Maintenance Chart
  - 260
    ADJUSTMENT CARBURETORS (On KZ400)
  - 260
    CARBURETORS (On US Model)
  - 260
    Fuel System
- 260
  KZ550-C] ADJUSTMENT IGNITION TIMING (On KZ550-C)
- 265
  Disassembly
  - 265
    Torque and Locking Agent
  - 265
    Fuel Tap
  - 265
    Carburetors
  - 266
    Mufflers
  - 266
    VACUUM SWITCH VALVE (On US Model)
  - 267
    AIR SUCTION VALVE (On US Model)
  - 267
    CY LINDER HEAD COVER (On US Model)
- 268
  Supplement for 1980 Model 271
  - 268
    CAMSHAFT SPROCKETS (On KZ400)
  - 268
    CAMSHAFTS (On KZ400)
  - 269
    Carburetor Holders
    - 269
      PISTON RINGS (On KZ400)
    - 269
      ENGINE SPROCKET (On KZ400)
    - 269
      STARTER MOTOR (On KZ550)
    - 270
      Starter Motor (KZ550)
    - 271
      Timing Advancer (On KZ550-C)
  - 271
    Engine Removal
    - 272
      Front Wheel (On KZ550-C)
      - 273
        Front Disc Brake (On KZ550-C)
      - 274
        Front Brake Caliper (KZ550-C)
  - 275
    Rear Wheel, Rear Drum Brake
    - 278
      TUBE LESS TI RES (On KZ550-C)
    - 280
      Handlebar (On KZ550-C)
    - 280
      Front Fork (On KZ550-C)
  - 280
    Throttle Cables
  - 281
    Front Fork (KZ550-C)
  - 282
    Drive Chain (On KZ400)
  - 282
    Swing Arm (On KZ550-C)
261
FRONT FORK (On KZ550-C)
- 5
  Model Ldentification
- 5
  KZ500-B1 Left Side View
- 5
  KZ500-B1 Right Side View
- 6
  Specifications
  - 6
    Table of Contents
  - 9
    Engine Performance Curves
  - 11
    Periodic Maintenance Chart
  - 12
    Adjustment-Engine
  - 13
    Spark Plugs
  - 13
    Ignition Timing
  - 13
    Spark Plug Gap
  - 13
    Timing Advancer
  - 14
    Point Gap Adjustment (Using a Thickness Gauge)
  - 14
    Point Gap Adjustment (Using a Dwell Angle Tester)
  - 14
    Timing Test (Static)
  - 15
    Timing Test (Dynamic)
  - 15
    Dynamic Ignition Timing Test
  - 16
    Valve Clearance
  - 17
    Inlet Valve Clearance Adjustment Chart
  - 18
    Exhaust Valve Clearance Adjustment Chart
  - 19
    Throttle Cables
  - 20
    Carburetors
  - 20
    Initial Synchronization-Mechanical
  - 21
    Throttle Valve Clearance
  - 21
    Throttle Valve Position at Fully Throttle
  - 22
    Idling Adjustment
  - 22
    Fine Synchronization-Vacuum
  - 23
    Clutch
  - 23
    To Synchronize the Carburetors
  - 25
    Engine Oil
  - 25
    Fuel System
  - 25
    Oil and Oil Filter Change
  - 25
    Oil Level Inspection
  - 27
    Adjustment-Chassis
  - 28
    Rear Shock Absorbers
  - 28
    Drive Chain
  - 28
    Drive Chain Slack
  - 29
    Front Brake
  - 29
    Rear Brake
  - 29
    Brake Pedal Position
  - 29
    Rear Brake Pedal Play
  - 30
    Brake Light Switch
  - 31
    Wheel Balance
  - 32
    Headlight
  - 32
    Balance Weight Installation
  - 32
    Horizontal Adjustment (Not On UK Model)
  - 32
    Vertical Adjustment
  - 33
    General Lubrication
  - 33
    Throttle Grip
  - 33
    Brake Lever
  - 33
    Clutch Lever
  - 34
    Clutch and Throttle Cables
  - 34
    Left Footpeg, Side Stand
  - 34
    Right Footpeg, Brake Pedal, Brake Push Rod Joint
  - 34
    Center Stand
  - 35
    Carburetor Choke Link Mechanism
  - 35
    Others
  - 36
    Disassembly-Introduction
  - 37
    Introduction to Disassembly
  - 38
    Torque and Locking Agent
  - 42
    Coarse Threads
  - 42
    Fine Threads
  - 43
    Disassembly-Engine Installed
  - 44
    Flow Chart
  - 45
    Fuel Tank
  - 46
    Fuel Tap
  - 47
    Air Cleaner Element
  - 49
    Separation of Carburetors
  - 50
    Carburetors
  - 51
    Choke Mechanism Adjustment
  - 52
    Fast Ldle Mechanism
  - 52
    Fast Ldle Mechanism Adjustment
  - 52
    Throttle Valve, Jet Needle Removal
  - 53
    Choke Valve Removal
  - 54
    Mufflers
  - 55
    Ignition Coils
  - 55
    Camshafts
  - 57
    Camshaft Cap Tightening Order
  - 57
    Cam Chain Timing
  - 59
    Camshaft Sprockets
  - 59
    Cylinder Head
  - 59
    Camshaft Sprocket Installation
  - 60
    Valves, Valve Guides
  - 60
    Cylinder Head Nut Tightening Order
  - 61
    Valve and Valve Guide
  - 62
    Cylinder Block
  - 62
    Cylinder Block Pry Point
  - 63
    Piston Ring Openings (Front Side View)
  - 64
    Camshaft Chain Guides (Upper, Front, Rear)
  - 65
    Pistons, Piston Rings
  - 65
    Front Camshaft Chain Guide Installation
  - 66
    Breather Cover
  - 66
    Top Ring, Second Ring
  - 66
    Oil Ring Expander Installation
  - 67
    Engine Sprocket Cover
  - 68
    Clutch Release
  - 69
    Engine Sprocket
  - 69
    External Shift Mechanism
  - 71
    Neutral Switch
  - 71
    Starter Motor
  - 73
    Alternator Stator
  - 74
    Alternator Rotor
  - 74
    Contact Breakers
  - 75
    Capacitors
  - 79
    Oil Pressure Switch
  - 79
    Oil Filter, Bypass Valve
  - 80
    Oil Pressure Relief Valve
  - 81
    Engine Oil Pump
  - 82
    Secondary Shaft Starter Motor Clutch
  - 84
    Secondary Shaft, Starter Motor Clutch
  - 85
    Starter Motor Idle Gear
  - 85
    Ball Bearing Installation
  - 87
    Disassembly-Engine Removed
  - 90
    Engine Removal
  - 93
    Engine Mounting Bolt Length and Torque
  - 94
    Crankcase Split
  - 102
    Transmission
  - 104
    Shift Drum
  - 104
    Drive Shaft
  - 106
    Circlip and Splined Washer Installation
  - 106
    Drive Shaft Gears
  - 107
    Crankshaft (Including Connecting Rods), Camshaft Chain, and Primary Chain
  - 107
    Output Shaft
  - 107
    Output Shaft Gears
  - 108
    Connecting Rods
  - 110
    Disassembly- Chassis
  - 112
    Front Wheel
  - 113
    Speedometer Gear Housing Disassembly
  - 114
    Wheel Bearing Removal
  - 114
    Bearing, Brake Disc Installation
  - 114
    Bearing, Brake Disc Removal
  - 115
    Front Disc Brake
  - 115
    Pad Installation
  - 116
    Caliper Removal (Each Caliper)
  - 116
    Caliper Installation Notes
  - 117
    Caliper Disassembly
  - 118
    Caliper Assembly
  - 118
    Master Cylinder Installation Notes
  - 118
    Master Cylinder Removal
  - 119
    Front Master Cylinder
  - 120
    Rear Wheel
  - 120
    Master Cylinder Disassembl
  - 120
    Brake Hose Replacement
  - 120
    Master Cylinder Assembly Notes
  - 121
    Wheel Installation
  - 123
    Wheel Coupling, Rear Sprocket Installation Notes
  - 124
    Rear Disc Brake
  - 124
    Bearing, Brake Disc Lnstallation Notes
  - 124
    Pad Removal
  - 125
    Caliper Removal
  - 126
    Rear Caliper
  - 127
    Caliper Fluid Seal, Dust Seal
  - 128
    Master Cylinder Disassembly
  - 128
    Master Cylinder Assembly
  - 128
    Rear Master Cylinder Installation
  - 129
    Rear Master Cylinder
  - 130
    Tires, Tubes
  - 131
    Clutch Cable
  - 131
    Throttle Cables
  - 133
    Speedometer Cable
  - 133
    Tachometer Cable
  - 134
    Headlight Unit
  - 134
    Indicator Lights (Left and Right Turn, High Beam, Neutral(
  - 134
    Headlight, Front Turn Signal
  - 135
    Turn Signal Lights
  - 135
    Bulb Replacement
  - 135
    Turn Signal Assemblys
  - 136
    Rear Turn Signal
  - 137
    Speedometer, Tachometer, Meter Lights, Indicator Lights (Oil, Stop Lamp)
  - 137
    Tail/Brake Light
  - 138
    Ignition Switch
  - 138
    Front Brake Light Switch
  - 138
    Rear Brake Light Switch
  - 139
    Starter Lockout Switch
  - 139
    Handlebar
  - 141
    Steering Stem
  - 143
    Steering Stem Bearings
  - 144
    Front Fork
  - 147
    Rear Shock Absorbers
  - 148
    Swing Arm
  - 150
    Maintenance- Engine
  - 151
    Air Cleaner
  - 151
    Cleaning and Replacement
  - 152
    Fuel Tank, Fuel Tap
  - 152
    Inspection and Cleaning
  - 153
    Carburetor
  - 153
    Carburetor Constructions
  - 154
    Starter System
  - 155
    Fast Idle Mechanism
  - 155
    Pilot System
  - 156
    Pilot System Fuel and Air Supply
  - 156
    Flow Characteristi
  - 156
    Main System
  - 157
    Cutaway
  - 157
    Main System Fuel and Air Supply
  - 158
    Float System
  - 158
    Service Fuel Level Measurement and Adjustment
  - 158
    Service Fuel Level Measurement
  - 159
    Camshaft
  - 159
    Valve Needle
  - 160
    Cam Height Measurement
  - 160
    Journal, Bearing Wear
  - 160
    Camshaft Runout
  - 161
    Camshaft Chain, Guide, Tensioner
  - 161
    Camshaft Chain Wear
  - 161
    Chain Length Measurement
  - 161
    Camshaft Chain Tensioner (Cross-wedge Type)
  - 162
    Cylinder Head, Valve
  - 162
    Chain Guide Wear
  - 162
    Chain Guide Rubber Wear
  - 162
    Cleaning and Inspection
  - 163
    Measuring Plastic Plate
  - 163
    Valve, Valve Guide, Valve Seat
  - 163
    Valve Inspection
  - 164
    Valve Shape
  - 164
    Valve Stem Bend
  - 164
    Valve Guide Inspection
  - 165
    Valve Seat Repair
  - 165
    Valve Seating Width
  - 165
    Cutting Angle of Valve Seat
  - 165
    Valve/Valve Seat Contact Area
  - 166
    Inlet Valve Stem Installed Height
  - 166
    Exhaust Valve Stem Installed Height
  - 167
    Valve Stem Height Inspection
  - 167
    Valve Installed Height
  - 167
    Valve Spring
  - 167
    Spring Tension
  - 168
    Cylinder Block, PistonValve Spring Squareness
  - 168
    Oil Seal
  - 168
    Compression Measurement
  - 169
    Cylinder, Piston Wear
  - 169
    Cylinder Inside Diameter Measurement
  - 170
    Piston/cylinder Clearance
  - 170
    Piston Cleaning
  - 170
    Boring, Honing
  - 170
    Piston Ring, Piston Ring Groove Wear
  - 171
    Piston, Piston Pin, Connecting Rod Wear
  - 171
    Piston Ring End Gap (Top, Second)
  - 172
    Crankshaft, Connecting Rod
  - 172
    Connecting Rod Bend, Twist
  - 172
    Connecting Rod Bend Measurement
  - 172
    Connecting Rod Bearing Insert/journal Wear
  - 173
    Crankshaft Runout
  - 174
    Crankshaft Bearing Insert/journal Wear
  - 175
    Secondary Shaft
  - 175
    Oil Passage Cleaning
  - 175
    Crankshaft Side Clearance
  - 176
    Primary Chain
  - 177
    Clutch Trouble
  - 177
    Friction Plate Wear, Damage
  - 178
    Clutch Housing Gear Damage
  - 178
    Clutch Plate Warp
  - 178
    Friction Plate / Clutch Housing Clearane
  - 179
    Clutch Housing Gear/secondary Shaft Gear Backlash
  - 179
    Clutch Housing/drive Shaft Sleeve Wear
  - 179
    Shift Mechanism
  - 179
    Clutch Hub Damage
  - 180
    Transmission
  - 182
    Neutral Locator
  - 182
    Shift Arm and Overshift Limiter Operation
  - 182
    Overshift Limiter
  - 182
    Transmission Trouble
  - 183
    Gear Backlash
  - 183
    Shift Fork Bending
  - 183
    Shift Fork/gear Groove Wear
  - 184
    Shift Fork Guide Pin/shift Drum Groove Wear
  - 184
    Shaftheedle Bearing Outer Race Wear
  - 184
    Gear Dog, Gear Dog Hole, Gear Dog Recess Damage
  - 184
    Gear/shaft Clearance
  - 185
    Engine Lubrication
  - 185
    Oil Pressure Switch, Relief Valve
  - 185
    Oil Pressure Measurement
  - 186
    Engine Lubrication System
  - 186
    Engine Oil Flow Chart
  - 187
    Oil Pressure Switch Inspection
  - 187
    Relief Valve Inspection
  - 187
    Outer Rotor/inner Rotor Clearance
  - 188
    Oil Filter
  - 188
    Outer Iotor/pump Body Clearance
  - 188
    Rotor Side Clearance
  - 188
    Oil Filter Replacement
  - 189
    Ball Bearing, Needle Bearing
  - 189
    Muffler
  - 189
    Oil Breather
  - 189
    Oil Seal Damage
  - 190
    Maintenance-Chassis
  - 191
    Wheel
  - 191
    Tire
  - 191
    Rim
  - 191
    Rim Runout Measurement
  - 192
    Grease Seal
  - 192
    Axle
  - 192
    Wheel Bearing
  - 193
    Rear Wheel Coupling
  - 193
    Damper Inspection
  - 194
    Sprocket
  - 194
    Wear
  - 194
    Lubrication
  - 194
    Cleaning
  - 195
    Brake
  - 195
    Automatic Wear Adjustment
  - 195
    Rear Sprocket Warp
  - 195
    Sprocket Teeth
  - 196
    Braking Stroke
  - 196
    Braking Release Stroke
  - 197
    Master Cylinder
  - 197
    Front and Rear Master Cylinders
  - 197
    Master Cylinder Part Wear
  - 198
    Caliper
  - 199
    Pad Wear
  - 199
    Fluid Seal Damage
  - 199
    Front Brake Pad
  - 199
    Rear Brake Pad
  - 200
    Brake Disc
  - 200
    Dust Seal, Cover, O Ring Damage
  - 200
    Piston, Cylinder Wear
  - 200
    Disc Warp
  - 201
    Brake Fluid
  - 201
    Disc Cleaning
  - 202
    Changing the Brake Fluid
  - 202
    Bleeding the Brake
  - 203
    Steering
  - 203
    Brake Line Damage
  - 204
    Compression Stroke
  - 204
    Extension Stroke
  - 204
    Bearing Wear, Damage
  - 204
    Bearing Lubrication
  - 206
    Spring
  - 206
    Oil Seal, Dust Seal
  - 206
    Fork Oil
  - 206
    Lnner Tube
  - 207
    Rear Shock Absorber
  - 207
    Oil Level
  - 207
    Fork Oil Level
  - 208
    Bushing Inspection
  - 208
    Shock Absorber Spring Force
  - 209
    Swing Arm Bearing Wear
  - 209
    Swing Arm Lubrication
  - 209
    Pivot Shaft
  - 209
    Pivot Shaft Runout
  - 210
    Maintenance-Electrical
  - 211
    Battery
  - 211
    Hydrometer
  - 211
    Electrolyte
  - 211
    Specific Gravity/Battery Charge Relationship
  - 212
    Initial Charge
  - 212
    Ordinary Charge
  - 212
    Test Charging
  - 212
    Battery Troubleshooting Guide
  - 213
    Charging System
  - 213
    Initial Inspection
  - 214
    Alternator
  - 214
    Alternator Failure
  - 214
    Alternator Output Test
  - 214
    Stator Coil Resistance Check
  - 215
    Regulator/Rectifier
  - 216
    Diode Current Flow
  - 216
    Zener Diode
  - 216
    Thyristor
  - 216
    Basic Regulator/Rectifier Circuit
  - 217
    Ignition System
  - 217
    Rectifier Inspection
  - 217
    Regulator Test
  - 218
    Lgnition Coil
  - 218
    Coil Inspection
  - 218
    Lgnition Circuit
  - 218
    Lgnition Coil Test
  - 219
    Contact Breaker
  - 220
    Contact Breaker Inspection
  - 220
    Capacitor
  - 220
    Capacitor Inspection
  - 220
    Ignition Timing/Engine Speed Relationship
  - 221
    Inspection and Lubrication
  - 221
    Spark Plug
  - 222
    Electric Starter System
  - 222
    Starter Motor Circuit
  - 222
    Starter Relay Test
  - 223
    Starter Lockout Switch Test
  - 223
    Carbon Brushes
  - 223
    Starter Switch Test
  - 224
    Starter Motor Construction
  - 224
    Brush Spring
  - 225
    Starter Motor Clutch
  - 225
    Field Coils
  - 226
    Clutch Inspection
  - 226
    Testing the Switch
  - 226
    Starter Motor Clutch Operation
  - 227
    Lighting System
  - 227
    Switch Inspection
  - 227
    Headlight Circuit
  - 228
    Headlight Trouble
  - 228
    Tail Light Trouble
  - 229
    Brake Light Circuit
  - 229
    Rear Brake Light Switch Inspection
  - 229
    Front Brake Light Switch Inspection
  - 229
    Brake Light Failure Indicator Switch Inspection
  - 231
    Turn Signal Circuit
  - 231
    Turn Signal Trouble
  - 232
    Horn
  - 232
    Horn Construction
  - 232
    Horn Adjustment
  - 233
    Speedometer, Tachometer
  - 233
    Horn Current Measurement
  - 233
    Horn Trouble
  - 234
    Troubleshooting-Guide

Kawasaki

Motorcycle

Service Manual

Kawasaki Heavy Industries, Ltd. 1979, 1980, 1981

Revised

Feb. 17, 1981

Table of Contents

- 4
  Quick Reference Guide
238
Appendix
- 239
  Additional Considerations for Racing
- 240
  To Inspect the Spark Plugs
- 240
  Spark Plug Reach
- 241
  Special Tools
- 245
  KZ500-B1 Wiring Diagram
- 246
  Supplement
- 247
  Supplement for 1980 Model
- 247
  Table of Contents
- 248
  Adjustment
  - 249
    KZ400-J1 (Left Side View)
  - 249
    KZ400-J1 (Right Side View)
  - 249
    Model Identification
  - 250
    Front Disc and Rear Drum Brake
  - 251
    Specifications
  - 253
    SPECIFICATIONS (On KZ550)
  - 255
    Engine Performance Curves (On KZ400)
  - 255
    KZ400-J1 (Except West German Model)
  - 256
    Engine Performance Curves (On KZ550)
  - 256
    KZ550-A1, C1 (US and Canadian Models)
  - 257
    Running Performance Curves (On KZ400)
    - 258
      Running Performance Curves (On KZ550)
  - 259
    Periodic Maintenance Chart
  - 260
    ADJUSTMENT CARBURETORS (On KZ400)
  - 260
    CARBURETORS (On US Model)
  - 260
    Fuel System
- 260
  KZ550-C] ADJUSTMENT IGNITION TIMING (On KZ550-C)
- 265
  Disassembly
  - 265
    Torque and Locking Agent
  - 265
    Fuel Tap
  - 265
    Carburetors
  - 266
    Mufflers
  - 266
    VACUUM SWITCH VALVE (On US Model)
  - 267
    AIR SUCTION VALVE (On US Model)
  - 267
    CY LINDER HEAD COVER (On US Model)
- 268
  Supplement for 1980 Model 271
  - 268
    CAMSHAFT SPROCKETS (On KZ400)
  - 268
    CAMSHAFTS (On KZ400)
  - 269
    Carburetor Holders
    - 269
      PISTON RINGS (On KZ400)
    - 269
      ENGINE SPROCKET (On KZ400)
    - 269
      STARTER MOTOR (On KZ550)
    - 270
      Starter Motor (KZ550)
    - 271
      Timing Advancer (On KZ550-C)
  - 271
    Engine Removal
    - 272
      Front Wheel (On KZ550-C)
      - 273
        Front Disc Brake (On KZ550-C)
      - 274
        Front Brake Caliper (KZ550-C)
  - 275
    Rear Wheel, Rear Drum Brake
    - 278
      TUBE LESS TI RES (On KZ550-C)
    - 280
      Handlebar (On KZ550-C)
    - 280
      Front Fork (On KZ550-C)
  - 280
    Throttle Cables
  - 281
    Front Fork (KZ550-C)
  - 282
    Drive Chain (On KZ400)
  - 282
    Swing Arm (On KZ550-C)
261
FRONT FORK (On KZ550-C)
- 5
  Model Ldentification
- 5
  KZ500-B1 Left Side View
- 5
  KZ500-B1 Right Side View
- 6
  Specifications
  - 6
    Table of Contents
  - 9
    Engine Performance Curves
  - 11
    Periodic Maintenance Chart
  - 12
    Adjustment-Engine
  - 13
    Spark Plugs
  - 13
    Ignition Timing
  - 13
    Spark Plug Gap
  - 13
    Timing Advancer
  - 14
    Point Gap Adjustment (Using a Thickness Gauge)
  - 14
    Point Gap Adjustment (Using a Dwell Angle Tester)
  - 14
    Timing Test (Static)
  - 15
    Timing Test (Dynamic)
  - 15
    Dynamic Ignition Timing Test
  - 16
    Valve Clearance
  - 17
    Inlet Valve Clearance Adjustment Chart
  - 18
    Exhaust Valve Clearance Adjustment Chart
  - 19
    Throttle Cables
  - 20
    Carburetors
  - 20
    Initial Synchronization-Mechanical
  - 21
    Throttle Valve Clearance
  - 21
    Throttle Valve Position at Fully Throttle
  - 22
    Idling Adjustment
  - 22
    Fine Synchronization-Vacuum
  - 23
    Clutch
  - 23
    To Synchronize the Carburetors
  - 25
    Engine Oil
  - 25
    Fuel System
  - 25
    Oil and Oil Filter Change
  - 25
    Oil Level Inspection
  - 27
    Adjustment-Chassis
  - 28
    Rear Shock Absorbers
  - 28
    Drive Chain
  - 28
    Drive Chain Slack
  - 29
    Front Brake
  - 29
    Rear Brake
  - 29
    Brake Pedal Position
  - 29
    Rear Brake Pedal Play
  - 30
    Brake Light Switch
  - 31
    Wheel Balance
  - 32
    Headlight
  - 32
    Balance Weight Installation
  - 32
    Horizontal Adjustment (Not On UK Model)
  - 32
    Vertical Adjustment
  - 33
    General Lubrication
  - 33
    Throttle Grip
  - 33
    Brake Lever
  - 33
    Clutch Lever
  - 34
    Clutch and Throttle Cables
  - 34
    Left Footpeg, Side Stand
  - 34
    Right Footpeg, Brake Pedal, Brake Push Rod Joint
  - 34
    Center Stand
  - 35
    Carburetor Choke Link Mechanism
  - 35
    Others
  - 36
    Disassembly-Introduction
  - 37
    Introduction to Disassembly
  - 38
    Torque and Locking Agent
  - 42
    Coarse Threads
  - 42
    Fine Threads
  - 43
    Disassembly-Engine Installed
  - 44
    Flow Chart
  - 45
    Fuel Tank
  - 46
    Fuel Tap
  - 47
    Air Cleaner Element
  - 49
    Separation of Carburetors
  - 50
    Carburetors
  - 51
    Choke Mechanism Adjustment
  - 52
    Fast Ldle Mechanism
  - 52
    Fast Ldle Mechanism Adjustment
  - 52
    Throttle Valve, Jet Needle Removal
  - 53
    Choke Valve Removal
  - 54
    Mufflers
  - 55
    Ignition Coils
  - 55
    Camshafts
  - 57
    Camshaft Cap Tightening Order
  - 57
    Cam Chain Timing
  - 59
    Camshaft Sprockets
  - 59
    Cylinder Head
  - 59
    Camshaft Sprocket Installation
  - 60
    Valves, Valve Guides
  - 60
    Cylinder Head Nut Tightening Order
  - 61
    Valve and Valve Guide
  - 62
    Cylinder Block
  - 62
    Cylinder Block Pry Point
  - 63
    Piston Ring Openings (Front Side View)
  - 64
    Camshaft Chain Guides (Upper, Front, Rear)
  - 65
    Pistons, Piston Rings
  - 65
    Front Camshaft Chain Guide Installation
  - 66
    Breather Cover
  - 66
    Top Ring, Second Ring
  - 66
    Oil Ring Expander Installation
  - 67
    Engine Sprocket Cover
  - 68
    Clutch Release
  - 69
    Engine Sprocket
  - 69
    External Shift Mechanism
  - 71
    Neutral Switch
  - 71
    Starter Motor
  - 73
    Alternator Stator
  - 74
    Alternator Rotor
  - 74
    Contact Breakers
  - 75
    Capacitors
  - 79
    Oil Pressure Switch
  - 79
    Oil Filter, Bypass Valve
  - 80
    Oil Pressure Relief Valve
  - 81
    Engine Oil Pump
  - 82
    Secondary Shaft Starter Motor Clutch
  - 84
    Secondary Shaft, Starter Motor Clutch
  - 85
    Starter Motor Idle Gear
  - 85
    Ball Bearing Installation
  - 87
    Disassembly-Engine Removed
  - 90
    Engine Removal
  - 93
    Engine Mounting Bolt Length and Torque
  - 94
    Crankcase Split
  - 102
    Transmission
  - 104
    Shift Drum
  - 104
    Drive Shaft
  - 106
    Circlip and Splined Washer Installation
  - 106
    Drive Shaft Gears
  - 107
    Crankshaft (Including Connecting Rods), Camshaft Chain, and Primary Chain
  - 107
    Output Shaft
  - 107
    Output Shaft Gears
  - 108
    Connecting Rods
  - 110
    Disassembly- Chassis
  - 112
    Front Wheel
  - 113
    Speedometer Gear Housing Disassembly
  - 114
    Wheel Bearing Removal
  - 114
    Bearing, Brake Disc Installation
  - 114
    Bearing, Brake Disc Removal
  - 115
    Front Disc Brake
  - 115
    Pad Installation
  - 116
    Caliper Removal (Each Caliper)
  - 116
    Caliper Installation Notes
  - 117
    Caliper Disassembly
  - 118
    Caliper Assembly
  - 118
    Master Cylinder Installation Notes
  - 118
    Master Cylinder Removal
  - 119
    Front Master Cylinder
  - 120
    Rear Wheel
  - 120
    Master Cylinder Disassembl
  - 120
    Brake Hose Replacement
  - 120
    Master Cylinder Assembly Notes
  - 121
    Wheel Installation
  - 123
    Wheel Coupling, Rear Sprocket Installation Notes
  - 124
    Rear Disc Brake
  - 124
    Bearing, Brake Disc Lnstallation Notes
  - 124
    Pad Removal
  - 125
    Caliper Removal
  - 126
    Rear Caliper
  - 127
    Caliper Fluid Seal, Dust Seal
  - 128
    Master Cylinder Disassembly
  - 128
    Master Cylinder Assembly
  - 128
    Rear Master Cylinder Installation
  - 129
    Rear Master Cylinder
  - 130
    Tires, Tubes
  - 131
    Clutch Cable
  - 131
    Throttle Cables
  - 133
    Speedometer Cable
  - 133
    Tachometer Cable
  - 134
    Headlight Unit
  - 134
    Indicator Lights (Left and Right Turn, High Beam, Neutral(
  - 134
    Headlight, Front Turn Signal
  - 135
    Turn Signal Lights
  - 135
    Bulb Replacement
  - 135
    Turn Signal Assemblys
  - 136
    Rear Turn Signal
  - 137
    Speedometer, Tachometer, Meter Lights, Indicator Lights (Oil, Stop Lamp)
  - 137
    Tail/Brake Light
  - 138
    Ignition Switch
  - 138
    Front Brake Light Switch
  - 138
    Rear Brake Light Switch
  - 139
    Starter Lockout Switch
  - 139
    Handlebar
  - 141
    Steering Stem
  - 143
    Steering Stem Bearings
  - 144
    Front Fork
  - 147
    Rear Shock Absorbers
  - 148
    Swing Arm
  - 150
    Maintenance- Engine
  - 151
    Air Cleaner
  - 151
    Cleaning and Replacement
  - 152
    Fuel Tank, Fuel Tap
  - 152
    Inspection and Cleaning
  - 153
    Carburetor
  - 153
    Carburetor Constructions
  - 154
    Starter System
  - 155
    Fast Idle Mechanism
  - 155
    Pilot System
  - 156
    Pilot System Fuel and Air Supply
  - 156
    Flow Characteristi
  - 156
    Main System
  - 157
    Cutaway
  - 157
    Main System Fuel and Air Supply
  - 158
    Float System
  - 158
    Service Fuel Level Measurement and Adjustment
  - 158
    Service Fuel Level Measurement
  - 159
    Camshaft
  - 159
    Valve Needle
  - 160
    Cam Height Measurement
  - 160
    Journal, Bearing Wear
  - 160
    Camshaft Runout
  - 161
    Camshaft Chain, Guide, Tensioner
  - 161
    Camshaft Chain Wear
  - 161
    Chain Length Measurement
  - 161
    Camshaft Chain Tensioner (Cross-wedge Type)
  - 162
    Cylinder Head, Valve
  - 162
    Chain Guide Wear
  - 162
    Chain Guide Rubber Wear
  - 162
    Cleaning and Inspection
  - 163
    Measuring Plastic Plate
  - 163
    Valve, Valve Guide, Valve Seat
  - 163
    Valve Inspection
  - 164
    Valve Shape
  - 164
    Valve Stem Bend
  - 164
    Valve Guide Inspection
  - 165
    Valve Seat Repair
  - 165
    Valve Seating Width
  - 165
    Cutting Angle of Valve Seat
  - 165
    Valve/Valve Seat Contact Area
  - 166
    Inlet Valve Stem Installed Height
  - 166
    Exhaust Valve Stem Installed Height
  - 167
    Valve Stem Height Inspection
  - 167
    Valve Installed Height
  - 167
    Valve Spring
  - 167
    Spring Tension
  - 168
    Cylinder Block, PistonValve Spring Squareness
  - 168
    Oil Seal
  - 168
    Compression Measurement
  - 169
    Cylinder, Piston Wear
  - 169
    Cylinder Inside Diameter Measurement
  - 170
    Piston/cylinder Clearance
  - 170
    Piston Cleaning
  - 170
    Boring, Honing
  - 170
    Piston Ring, Piston Ring Groove Wear
  - 171
    Piston, Piston Pin, Connecting Rod Wear
  - 171
    Piston Ring End Gap (Top, Second)
  - 172
    Crankshaft, Connecting Rod
  - 172
    Connecting Rod Bend, Twist
  - 172
    Connecting Rod Bend Measurement
  - 172
    Connecting Rod Bearing Insert/journal Wear
  - 173
    Crankshaft Runout
  - 174
    Crankshaft Bearing Insert/journal Wear
  - 175
    Secondary Shaft
  - 175
    Oil Passage Cleaning
  - 175
    Crankshaft Side Clearance
  - 176
    Primary Chain
  - 177
    Clutch Trouble
  - 177
    Friction Plate Wear, Damage
  - 178
    Clutch Housing Gear Damage
  - 178
    Clutch Plate Warp
  - 178
    Friction Plate / Clutch Housing Clearane
  - 179
    Clutch Housing Gear/secondary Shaft Gear Backlash
  - 179
    Clutch Housing/drive Shaft Sleeve Wear
  - 179
    Shift Mechanism
  - 179
    Clutch Hub Damage
  - 180
    Transmission
  - 182
    Neutral Locator
  - 182
    Shift Arm and Overshift Limiter Operation
  - 182
    Overshift Limiter
  - 182
    Transmission Trouble
  - 183
    Gear Backlash
  - 183
    Shift Fork Bending
  - 183
    Shift Fork/gear Groove Wear
  - 184
    Shift Fork Guide Pin/shift Drum Groove Wear
  - 184
    Shaftheedle Bearing Outer Race Wear
  - 184
    Gear Dog, Gear Dog Hole, Gear Dog Recess Damage
  - 184
    Gear/shaft Clearance
  - 185
    Engine Lubrication
  - 185
    Oil Pressure Switch, Relief Valve
  - 185
    Oil Pressure Measurement
  - 186
    Engine Lubrication System
  - 186
    Engine Oil Flow Chart
  - 187
    Oil Pressure Switch Inspection
  - 187
    Relief Valve Inspection
  - 187
    Outer Rotor/inner Rotor Clearance
  - 188
    Oil Filter
  - 188
    Outer Iotor/pump Body Clearance
  - 188
    Rotor Side Clearance
  - 188
    Oil Filter Replacement
  - 189
    Ball Bearing, Needle Bearing
  - 189
    Muffler
  - 189
    Oil Breather
  - 189
    Oil Seal Damage
  - 190
    Maintenance-Chassis
  - 191
    Wheel
  - 191
    Tire
  - 191
    Rim
  - 191
    Rim Runout Measurement
  - 192
    Grease Seal
  - 192
    Axle
  - 192
    Wheel Bearing
  - 193
    Rear Wheel Coupling
  - 193
    Damper Inspection
  - 194
    Sprocket
  - 194
    Wear
  - 194
    Lubrication
  - 194
    Cleaning
  - 195
    Brake
  - 195
    Automatic Wear Adjustment
  - 195
    Rear Sprocket Warp
  - 195
    Sprocket Teeth
  - 196
    Braking Stroke
  - 196
    Braking Release Stroke
  - 197
    Master Cylinder
  - 197
    Front and Rear Master Cylinders
  - 197
    Master Cylinder Part Wear
  - 198
    Caliper
  - 199
    Pad Wear
  - 199
    Fluid Seal Damage
  - 199
    Front Brake Pad
  - 199
    Rear Brake Pad
  - 200
    Brake Disc
  - 200
    Dust Seal, Cover, O Ring Damage
  - 200
    Piston, Cylinder Wear
  - 200
    Disc Warp
  - 201
    Brake Fluid
  - 201
    Disc Cleaning
  - 202
    Changing the Brake Fluid
  - 202
    Bleeding the Brake
  - 203
    Steering
  - 203
    Brake Line Damage
  - 204
    Compression Stroke
  - 204
    Extension Stroke
  - 204
    Bearing Wear, Damage
  - 204
    Bearing Lubrication
  - 206
    Spring
  - 206
    Oil Seal, Dust Seal
  - 206
    Fork Oil
  - 206
    Lnner Tube
  - 207
    Rear Shock Absorber
  - 207
    Oil Level
  - 207
    Fork Oil Level
  - 208
    Bushing Inspection
  - 208
    Shock Absorber Spring Force
  - 209
    Swing Arm Bearing Wear
  - 209
    Swing Arm Lubrication
  - 209
    Pivot Shaft
  - 209
    Pivot Shaft Runout
  - 210
    Maintenance-Electrical
  - 211
    Battery
  - 211
    Hydrometer
  - 211
    Electrolyte
  - 211
    Specific Gravity/Battery Charge Relationship
  - 212
    Initial Charge
  - 212
    Ordinary Charge
  - 212
    Test Charging
  - 212
    Battery Troubleshooting Guide
  - 213
    Charging System
  - 213
    Initial Inspection
  - 214
    Alternator
  - 214
    Alternator Failure
  - 214
    Alternator Output Test
  - 214
    Stator Coil Resistance Check
  - 215
    Regulator/Rectifier
  - 216
    Diode Current Flow
  - 216
    Zener Diode
  - 216
    Thyristor
  - 216
    Basic Regulator/Rectifier Circuit
  - 217
    Ignition System
  - 217
    Rectifier Inspection
  - 217
    Regulator Test
  - 218
    Lgnition Coil
  - 218
    Coil Inspection
  - 218
    Lgnition Circuit
  - 218
    Lgnition Coil Test
  - 219
    Contact Breaker
  - 220
    Contact Breaker Inspection
  - 220
    Capacitor
  - 220
    Capacitor Inspection
  - 220
    Ignition Timing/Engine Speed Relationship
  - 221
    Inspection and Lubrication
  - 221
    Spark Plug
  - 222
    Electric Starter System
  - 222
    Starter Motor Circuit
  - 222
    Starter Relay Test
  - 223
    Starter Lockout Switch Test
  - 223
    Carbon Brushes
  - 223
    Starter Switch Test
  - 224
    Starter Motor Construction
  - 224
    Brush Spring
  - 225
    Starter Motor Clutch
  - 225
    Field Coils
  - 226
    Clutch Inspection
  - 226
    Testing the Switch
  - 226
    Starter Motor Clutch Operation
  - 227
    Lighting System
  - 227
    Switch Inspection
  - 227
    Headlight Circuit
  - 228
    Headlight Trouble
  - 228
    Tail Light Trouble
  - 229
    Brake Light Circuit
  - 229
    Rear Brake Light Switch Inspection
  - 229
    Front Brake Light Switch Inspection
  - 229
    Brake Light Failure Indicator Switch Inspection
  - 231
    Turn Signal Circuit
  - 231
    Turn Signal Trouble
  - 232
    Horn
  - 232
    Horn Construction
  - 232
    Horn Adjustment
  - 233
    Speedometer, Tachometer
  - 233
    Horn Current Measurement
  - 233
    Horn Trouble
  - 234
    Troubleshooting-Guide

Troubleshooting

Related Manuals for Kawasaki KZ400

Motorcycle Kawasaki KZ500 Manual
1979-1985 (340 pages)
Motorcycle Kawasaki KZ650F1 Owners Workshop Manual
Motorcycle (132 pages)
Motorcycle Kawasaki KZ400D Shop Manual
Kawasaki kz400 (1974-1977) motorcycle shop manual (197 pages)
Motorcycle Kawasaki KZ750 Four Service Manual
Kawasaki kz750 four (8 pages)
Motorcycle Kawasaki KZ750-H4 Manual
1983 model kawasaki kz750-h4; kz750-l3; zx750-a1 (54 pages)
Motorcycle Kawasaki KZ700-A1 1984 Supplement Manual
Kawasaki 1984 model motorcycle supplement (24 pages)
Motorcycle Kawasaki KZ440 Service Manual
(314 pages)
Motorcycle Kawasaki KZ650 Service Manual
(226 pages)

Motorcycle Kawasaki KZ1000R Owner's Manual
(100 pages)
Motorcycle Kawasaki KZ650-B2 Owner's Manual
(110 pages)
Motorcycle Kawasaki KZ400-H1 LTD Service Manual Supplement
(23 pages)
Motorcycle Kawasaki KZ1100 Service Manual
(371 pages)
Motorcycle Kawasaki KZ1300-A1 Quick Reference Manual
(366 pages)
Motorcycle Kawasaki KLR650 Service Manual
(462 pages)
Motorcycle Kawasaki KLR650 Service Manual Supplement
(130 pages)

This manual is also suitable for:

Kz500 Kz550

Kawasaki KZ400 Service Manual

238
Appendix

261
FRONT FORK (On KZ550-C)

238
Appendix

261
FRONT FORK (On KZ550-C)

Troubleshooting

Related Manuals for Kawasaki KZ400

Related Products for Kawasaki KZ400

This manual is also suitable for:

Comments to this Manuals

Latest comments:

Kawasaki KZ400 Service Manual

238 Appendix

261 FRONT FORK (On KZ550-C)

238 Appendix

261 FRONT FORK (On KZ550-C)

Troubleshooting

Related Manuals for Kawasaki KZ400

Related Products for Kawasaki KZ400

This manual is also suitable for:

Comments to this Manuals

Latest comments:

238
Appendix

261
FRONT FORK (On KZ550-C)

238
Appendix

261
FRONT FORK (On KZ550-C)