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Secondary Shaft; Oil Passage Cleaning; Crankshaft Side Clearance - Kawasaki KZ400 Service Manual

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Table of Contents
178 MAINTENANCE-ENGINE
A. Markings for Crankcase
("0"
or No mark)
B. Painted Marks (Brown, Black, or Green)
Table H45
Crankshaft Bearing Inside Diameter
1
Markina
1
Standard
I
3. Select the proper bearing inserts in accordance with
the combination o f the crankcase and the crankshaft
marks (Table H46).
0
No mark
Table H46
Crankshaft Bearing Insert Selection
No mark
36.000
-
36.008 mm
36.009
-
36.01 6 mm
No mark
Crankshaft side clearance
Measure the crankshaft side clearance with a thick-
ness gauge as shown. Replace the crankcase halves as a
set, i f the clearance exceeds the service limit.
Table
H47
Crankshaft Bearing Insert Thickness
Table H48
Crankshaft Side Clearance
Black
PIN: 13034-1 01 7
Color
Brown
Black
Green
--
I
Service Limit
1
0.35 mm
]
Green
PIN: 13034-1 01 8
Thickness
1.991
-
1.995 m m
1.995
-
1.999 m m
1.999
-
2.003 m m
A. Crankshaft
B. Thickness Gauge
NOTE: The upper crankcase half and the lower crank-
case half are machined at the factory in the assembled
state, so the crankcase halves must be replaced as a set.
Oil passage cleaning
There are oil passages running between the crank-
shaft journals. Use compressed air to remove any foreign
particles or residue that may have accummulated in
these passages.
A. Crankshaft
6.
Compressed Air
SECONDARY SHAFT
The secondary shaft has the secondary sprocket, cou-
pling, starter motor clutch, and secondary shaft gear on
it. The secondary sprocket i s chain-driven by the crank-
shaft, and the secondary shaft gear transmits the power
to the clutch housing gear. The sccondary shaft coupling
connects the sccondary sprocket to the shaft. Rubber
dampers in the coupling absorb the pulsations of the
engine torque.
Check both o f the end ball bearings o f the secondary
shaft, and replace i f necessary (Pg. 192).
Secondary sprocket damage
Inspect the teeth on the secondary sprocket.
Any
light damage can be corrected with an oilstone, but the
secondary sprocket must be replaced i f the teeth are

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