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Crankcase Split - Kawasaki KZ400 Service Manual

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Table of Contents
96 DISASSEMBLY-ENGINE
R E M O V E D
A.
Contact Breaker Leads
B. Clamps
*Connect the rear brdkc light switch iedds (blue and
brown).
.Install
the battery negative ground lead on the engine
right side tightening its bolt.
The bolt has a lock-
washer.
*Adjust the drive chain (Pg. 28).
.Install
the air cledner housing, and put the mounting
brackets into both sides o f the housing.
Install the
bracket bolts, lockwashers, and tlat washers with
finger tight.
The brdcket bolts are tightened after
carburetor installation.
A . Air Clea,ner Housing
B. Mounting Bracket
*Check that the air cleaner element i s fitted in the cor-
rect position
ds
shown in Fig.
E l 2.
*Install
the air cleaner element cap, and tighten the
screws and flat washers.
*Install the baffle plate with its bolts.
Each bolt hds
a lockwasher dnd flat washer.
.Fit
the breather hose onto the b~.eather cover, slide
back the clip.
*Put o n the cdrburetor holder clamp (4).
*Install the carburetors (Pg. 50).
*Fix the air cleaner housing to battery housing with
the left and right side bracket bolts.
.Install
the ignition coils (Pg. 57), and connect the
contact breaker point leads (green and brake).
I n s t a l l the tachometer cable lower end o n t o thecylinder
head.
*Install the mufflers (Pg. 57).
.Install
the fuel tank (47).
*Push the seat bdck down.
.Fit
the right and left side covers.
.Install
the left dnd right reflectors. Each o f them has
d
rubber damper.
*Install the rear brake light switch spring.
.Adjust the rear brake pedal (Pg. 29).
.Adjust
the rear brake light switch (Pg. 30).
*Fill the engine with oil, check the level (Pg. 24), and
add more i f necessary.
*Adjust the clutch (Pg. 22).
*Adjust the throttle cdbles (Pg. 18).
.Adjust
the ignition timing (Pg. 12).
CRANKCASE SPLIT
Disassembly:
.Remove the engine (Pg.
92).
.Set
the engine on
d
clean surface or, preterably, into a
disdssembly dpparatus with some means o f holding the
engine steddy while pdrts are being removed.
NOTE: If the engine i s to be set onto the engine stand
(specid1 tool), t w o o f the upper crankcase half bolts
(1 3 ) shown in Fig. F20 must be removed before posi-
tioning the engine.
A.
Remove the bolts.
A. Engine Stand (57001-900)
*Remove the starter motor retaining bolts
( 2 ) ,
and pull
o f f the starter motor.

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Kz500Kz550

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