Kawasaki ZX400-H2 Manuel d'utilisateur

1-10 GENERAl INFORMATIONFastenerTorquekg-m0.151.50.451.51.751.21.2Remarks~N-m1.5154.41517121213 in-Ib11.039 in-Ib11.012.58.58.5ssss30363.13.722271

CRANKSHAFT / TRANSMISSION 8-17Shift Drum and Fork Removal.Remove the following.Lower Crankcase Half (see Crankcase Splitting)External S

WHEELS / TIRES 9-1Table of Contents9-29-39-49-59-59-59-69-69-69-79-89-89-89-89-89-99-119-119-119-119-119-119-11..~Exploded View Specifications

9-2 WHEELS / TIRESExploded View/165J@@~~~@~~~~@"@.~I:[:;l:~!fi;~T1:11 N-m(11.0kg-m,80ft-Ib)G : Apply grease.

WHEELS / TIRES 9-3SpecificationsService LimitStandardItemWheels:Rim runout (with tire installed)AxialRadialAxle runout/1 00 mm0.5mm0.8mm0.2

9-4 WHEELS / TIRESSpecial ToolsBearing Driver Set: 57001 -1129Bearing Remover Head. <1>15 x <1>17: 57001 -1267~Bearing Remov

WHEELS / TIRES 9-5Wheels (Rims)Front Wheel Removal.Remove the following.Lower Fairings (see Frame chapter)Speedometer Cable Lower EndRi

9-6 WHEELS / TIRES~A. Rear WheelB. Rear Caliper Bracket1 .Housing Stop2. Fork Leg Stop3. FrontOFit the collar in the right side of the hub

WHEELS / TIRES 9-7Rim RunoutO Check that the blade and weight seat fully on the rimflange, and that the clip is hooked over the r

9-8 WHEELS / TIRESTiresTire Air Pressure InspectionBalance Weight Removal(a) When the tire is not on the rim..Push the blade portion

WHEELS / TIRES 9-92. Valve Stem1. Chalk Mark or Yellow Mark.Lubricate the tire beads and rim flanges on both sideswith a soap and

GENERAl INFORMATION 1-11FastenerTorquekg-m5.0RemarksN-m49ft-Ib362919.07.016.539259.8234.02.61.02.3Tie- Rod NutsSteering:Steering Stem Head NutHan

9-10 WHEELS I TIRES.After the tire beads seat in the rim flanges, check for airleaks. Inflate the tire slightly above standard infl

WHEELS / TIRES 9-11Speedometer Gear HousingHub BearingsDisassembly and AssemblyNOTEOlt is recommended that the assembly be replaced rather

FINAL DRIVE 10-1Table of Contents.10-2.10-3.10-3.10-4.10-4.10-4.10-4.10-5.10-5.10-6.10-6.10-6.10-6.10-7.10-7.10-7.10-7Exploded View Specification

10-2 FINAL DRIVEExploded View@/<~"@,T1. 9.8 N-m (1.0 kg-m, 7.0 ft-Ib)T2: 74 N-m (7.5 kg-m, 54 ft-Ib)L : Apply a non-permanent loc

FINAL DRIVE 10-3SpecificationsSpecial ToolsJack: 57001 -1238~Inside Circlip Pliers: 57001-143~~~I I

10-4 FINAL DRIVEDrive ChainDrive Chain Slack Adjustment.Set the motorcycle up on its side stand and check thatthe chain slack is wi

FINAL DRIVE 10-5I,,~ Cj) I!-'--.~ ." "' .Oil Applied Areas1st 21st1 .Weight2. Straight Part3. Ruler4. Measure this len

10-6 FI NAl DRIVESprocket, CouplingEngine Sprocket Removal.Loosen the drive chain (see Drive Chain Slack Adjust-ment) ..Remove the fo

FINAL DRIVE 10-7Rear Sprocket Removal.Remove the rear wheel (see Wheels/Tires chapter)NOTEOSprocket wear is exaggerated for illustratio

BRAKES 11-1Table of Contents..11-2..11-4..11-4..11-5..11-5..11-5..11-5..11-5..11-6..11- 7..11- 7..11-8,..11-8,..11-8,..11-8...11-9...11-9,11-10.11-

1-12 GENERAL INFORMATIONCable. Wire. and Hose Routing1. Clutch Cable2. Choke Cable3. Throttle Cable4. Speedometer Cable/ClampRun the c

11-2 BRAKESExploded View,~~@rcr@~~T1: 1.0 N-m (0.10 kg-m. 9 in-Ib)T2: 1.2 N-m (0.12 kg-m.10 in-Ib)T3: 2.9 N-m (0.30 kg-m. 26 in-Ib)T4: 5.

BRAKES 11-3f~'@~/V~G : Apply grease.M : Apply molybdenum disulfide grease.

11-4 BRAKESSpecificationsItemStandardService limitBrake Fluid:GradeBrand (recommendedjD.O.T.3Atlas Extra Heavy DutyShell Super Heavy DutyTex

BRAKES 11-5Brake FluidBrake Fluid Requirement:Recommended fluids are given in the table below. Ifnone of the recommended brake fluids

11 -6 B RAKESWhen working with the disc brake, observe theprecautions listed below.Bleeding the Brake LineThe brake fluid has a very

BRAKES 11-7Brake PedalBrake Pedal Position Adjustment.Check that the brake pedal is in the correct position.Pedal PositionStandard:About

11-8 BRAKESCalipersRear Brake Light Switch Adjustment.Check the operation of the rear brake light switch bydepressing the brake pedal

BRAKES 11-9C. Caliper Mounting BoltsA. Caliper Assembly BoltsA. Banjo BoltB. Caliper Assembly Bolts.Remove the piston insulator and the

11-10 BRAKESO Pullout the pistons by hand.A. Rear CaliperB. Apply compressed air.Assembly Notes.Apply brake fluid to the cylinders,

BRAKES 11-11Brake PadsFront Brake Pad Removal.Remove the following.Pad SpringClipPad PinA. Piston InsulatorsB. O-Rings.Tighten the calipe

GENERAL INFORMATION 1-131. Battery Vent Hose(Transparent)2. Battery Vent Hose (Black)3. Fuel Tank Breather Hose4. Coolant Reservoir Tank

11-12 BRAKESLining Wear.For front caliper pad inspection, remove the pad spring(see Front Caliper Removal)..For rear caliper pad inspec

BRAKES 11-13Master CylindersRear Master Cylinder Installation Notes.Use a new flat washer on each side of the brake hosefitting..Tigh

11-14 BRAKESBrake DiscsAssembly.Before assembly, clean all parts including the mastercylinder with brake fluid or alcohol..Apply brake

BRAKES 11-15Disc RunoutStandard:Service Limit:Under 0.2 mm0.3mm

SUSPENSION 12-1Table of Contents...12-2...12-4...12-5...12-6...12-6...12-6...12-6...12-8...12-8...12-8.12-10.12-11.12-11.12-11.12-11.12-12.12-12.12

12-2 SUSPENSIONExploded View@~~--<-;:0-I """'II : 0 ~~~~~~I"! ~@ I~ l ~~ .Ua I IO I I/1= i !I I! I f II

12-4 SUSPENSIONSpecificationsItemStandardService LimitFront Fork:Rebound damping settingSpring preload setting6th click from fully counterc

SUSPENSION 12-5Special ToolsOil Syringe: 57001 -1290Steering Stem Nut Wrench: 57001 -1100Fork Cylinder Holder: 57001-1297Bearing Driver

12-6 SUSPENSIONFront ForkRebound Damping Force Adjustment.To adjust the rebound damping, turn the rebounddamping adjuster until you fe

1-14 GENERAL INFORMATIONView Looking at Front6. Battery ( -) Lead7. Ground Lead8. To Ignition Coil (#1, #4)9. To Ignition Coil (#2, #

SUSPENSION 12-7NOTE0 Measure the fork oi!!evel compressing the outer tubeand piston rod down with the push rod installed.OSet the oil

12-8 SUSPENSIONRemoval.Remove the following.Lower FairingFront WheelFront Fender Mounting Bolts and ScrewsFork Clamp Bolts (upper and l

SUSPENSION 12-9Push RodPiston Rod NutA. Push RodB. Piston Rodc. Piston Rod Nut.Pour the fork oil into a container..Remove the follow

12-10 SUSPENSIONA. 12 mm or moreB. Rod Nutc. Piston RodAssembly.Replace the bottom Allen bolt gasket with new one..Replace the foll

SUSPENSION 12-11Rear Shock AbsorberRebound Damping Force AdjustmentThe rebound damping force adjuster at the lower endof the rear shoc

12-12 SUSPENSION1 .Banjo BoltA. Rear Shock Absorber Mounting Bolt, Nut (upper)ScrappingSince the rear shock absorber contains nitrogen

SUSPENSION 12-13Swing ArmSwing Arm Sleeve Inspection* If there is visible damage, replace the sleeve, the ballbearing, and all the n

12-14 SUSPENSIONTie-Rod, Rocker ArmTie-Rod Removal.Remove the following.Lower Fairings (see Frame chapter)Rocker Arm (see Rear Shock Re

SUSPENSION 12-15Tie-Rod, Rocker Arm Sleeve Inspection*If there is visible damage, replace the sleeve and needlebearing(s) as a set.

STEERING 13-1Table of Contents..13-2..13-3...13-4...13-4...13-5...13-5...13-5...13-7...13-7...13- 7...13- 7...13- 7Exploded View Special Tools St

GENERAL INFORMATION 1-15Run the lead over thefairing stay.@6. Ground Lead 11. Fuel Pump Lead7. To Left Turn Signal Light 12. Pickup

13-2 STEERINGExploded Viewr~eIIr@@,~~£@"'@@--4@@T1: 9.8 N-m (1.0 kg-m. 7.0 ft-Ib)T2: 23 N-m (2.3 kg-m. 16.5 ft-Ib)T3: 39 N-m

STEERING 13-3Special ToolsHead Pipe Outer Race Driver: 57001 -1106(?]})Steering Stem N ut Wrench: 57001 -1100Bearing Puller Stud: 5700

13-4 STEERINGSteeringSteering Stem Head NutFront Fork Lower Clamp Bolts.Check the steering again.* If the steering is still too tigh

STEERING 13-5Steeri ng StemRemoval.Remove the following parts.Surge Tank (see Fuel System chapter)Upper and Lower Fairings (see Frame ch

13-6 STEERING.1 Grease SealOApply grease to the lower tapered roller bearing, anddrive it onto the steering stem using the stem bear

STEERING 13-7Choke CablesClutchFront BrakeSteering Stem BearingBearing Lubrication.Perform the following.O Remove the steering stem.O Using

FRAME 14-1Table of Contents.14-2.14-5.14-5.14-5.14-5.14-5.14-6.14-6.14-6.14-6.14-6Exploded View Seats Front Seat Removal Front Seat Installat

14-2 FRAMEExploded View~lApply a non-permanent locking agent to thethreads.

1-16 GENERAL INFORMATIONTo Main Harness1 fRun the lead inside-of the water pump."'"--'~1-t 0)- m~,v)~~]1/Clamp0--1. A

FRAME 14-5SeatsFront Seat Removal.Remove the front seat mounting bolt, move it upwardand slide it forward.A. Seat LockB. Seat Mounting

14-6 FRAMESide CoversFairingsUpper Fairing Removal.Remove the following in the order listed.Rear View Mirror NutsUpper Fairing Mounting

FRAME 14-7NOTE0 Remove the lower fairings as assembly.

ELECTRICAL SYSTEM 15-1T able of Contents.15-21.15-21.15-22.15-22.15-23.15-23.15-25.15-25.15-25.15-25.15-26.15-26.15-26.15-26.15-27.15-27.15-28.15

15-2 ELECTRICAL SYSTEMO Color Codes:BKBLBRCHDGGGYLBLGOpPURWYPrecautionsBlackBlueBrownChocolateDark greenGreenGrayLight blueLight greenOrangePin

ELECTRICAL SYSTEM 15-3Wiring Diagram (ZX400-H2)~~~ c.,.i~ §;I ~ m w~ IC A ":=0 ~~** ~.~ ..L-~,.,. ~ .i " A S~ M ~I r"

15-4 ELECTRICAL SYSTEMParts location1. Headlight Unit2. Meter Unit3. Starter Motor4. Tail/Brake Light5. Licence Light6. Fan Switch7. A

ELECTRICAL SYSTEM 15-5Exploded View~~T1: 6.4 N-m (0.65 kg-m, 56 in-Ib)T2: 8.3 N-m (0.85 kg-m, 74 in-Ib)T3: 8.8 N-m (0.90 kg-m, 78 in

FUEL SYSTEM 2-1Table of Contents..2-2..2-4...2-4..2-5..2-5..2-6...2-6...2-6...2-6...2-7...2-7...2- 7...2-7...2-8...2-8...2-8...2-9...2-9...2-9...2

15-8 ELECTRICAL SYSTEMSpecificationsItemStandardService Limit12V10Ah1.280 @20°C (68°F)Battery:TypeSpecific gravityAlternator:Charging voltageOu

ELECTRICAL SYSTEM 15-9Special T 0015Hand Tester: 57001-983Flywheel Holder: 57001 -1313Coil Tester: 57001 -1242Spark Plug Wrench, Hex 16:

15-10 ELECTRICAL SYSTEM*If the specific gravity is below 1.20 (charge 60%), thebattery needs to be charged.BatteryInitial Charging.Rem

ELECTRICAL SYSTEM 15-11Charging SystemAlternator Cover Removal.Remove the lower fairing..Set a suitable container under the engine..Remov

15-12 ELECTRICAL SYSTEMA. Silicone Sealant Applied AreaA. Flywheel Holder: 57001 -1 31 3 C. Rotor BoltB. Rotor.Apply silicone sealant t

ELECTRICAL SYSTEM 15-13Alternator Rotor Cleaning AreaA. Holding PlateB. Grommetsc. Mounting BoltsD. Stator1. The tapered portion of the

15-14 ELECTRICAL SYSTEM57001-983)Connect the hand tester (special tool:as shown in table.Note the readings (total 3 measurement)Rectifie

ELECTRICAL SYSTEM 15-15.Connect the brown lead terminal to the other battery( + ) terminal and connect the black/yellow lead terminal

15-16 ELECTRICAL SYSTEM.Repeat the above three steps for other two yellow leads(in connector 2 which leads to the regulator/rectifier)

ELECTRICAL SYSTEM 15-17Pickup Coil Resistance (x 100 0)355 -5350 (BK, y lead)*If the distance reading is less than the specified va

2-2 FUEL SYSTEMExploded View

15-18 ELECTRICAL SYSTEM.Check the spark plug leads for visible damage.*If any spark plug lead is damaged, replace the coilIgnition Sy

ELECTRICAL SYSTEM 15-19Spark Plug Removal.Remove the following.Surge Tank (see Fuel System chapter)Spark Plug Caps.Remove the spark plu

15-20 ELECTRICAL SYSTEMIC Igniter Internal ResistanceRange: kQElectric Starter SystemStarter Motor Removal.Remove the fuel tank (see Fu

ELECTRICAL SYSTEM 15-21Starter Motor Assembly Note.Inspect the O-rings if it is not damaged..Install the brushes and springs into the

15-22 ELECTRICAL SYSTEM2. Shaft1. Segment1. Commutator2. Emery ClothNOTEOEven if the foregoing checks show the armature to begood. it may be

ELECTRICAL SYSTEM 15-23Brush Plate and Terminal Bolt Inspection.Using the x 1 .0 ohmmeter range, measure the resist-ance as shown.bet

ELECTRICAL SYSTEM 15-25Lighting SystemThe headlight beam is adjustable both horizontally andvertically. Headlight aiming must be correct

15-26 ELECTRICAL SYSTEMA. Pin Closest to Base.1 .Dust Cover 2. Headlight Bulb.Insert the socket by aligning the tangs with the catc

ELECTRICAL SYSTEM 15-27Radiator Fan SystemFan System Circuit Inspection.Remove the left lower fairing and disconnect the leadsfrom the

15-28 ELECTRICAL SYSTEMHeadlight CircuitFan Installation.Tighten the fan mounting bolt to the specified toruqe(see Exploded View in the

ELECTRICAL SYSTEM 15-29Cooling Fan CircuitFuel PumpThe pump operates when the starter button is pushedon or the engine is running..Refe

15-30 ELECTRICAL SYSTEMFuel Pump Relay Internal Resistance.Connect the pump leads to the battery using auxiliarywires as shown.*If the

ELECTRICAL SYSTEM 15-31Meters, GaugesRemoval.Remove the following.Upper Fairing (see Frame chapter)Headlight UnitSpeedometer Cable Upper E

15-32 ELECTRICAL SYSTEM* If these readings are not correct. the trouble is with thegauge and/or wiring.A. TachometerB. Pointer flicks.Water Temp

ELECTRICAL SYSTEM 15-33Tachometer Circuit6. Ignition Coil {#1, #4)7. Spark Plug8. 30A Main Fuse in Starter Relay9. Battery1. Ignition

15-34 ELECTRICAL SYSTEMWater Temperature Sensor Inspection.Suspend the sensor in a container of coolant so that thetemperature sensing p

ELECTRICAL SYSTEM 15-35Junction BoxFuse Inspection.Remove the fuse (see Fuse Removal)..Inspect the fuse element.* If it is blown out

15-36 ELECTRICAL SYSTEMStarter Circuit.Remove the junction box (see Fuse Removal)..Check conductivity of the following numbered terminal

ELECTRICAL SYSTEM 15-37Junction Box Internal CircuitElectrical WiringWiring Inspection.Visually inspect the wiring for signs of burning,

Final Drive""

2-4 FUEL SYSTEMSpecificationsItemStandardThrottle Grip Free Play2 -3mm2 -3mmChoke Cable Free PlayIdle Speed1 200 :t 50 r/min (rpm)Carbu

APPENDIX 16-1Table of Contents.16-2.16-2.16-2.16-3.16-4.16-5.16- 7.16-7.16-8.16-8.16-8.16-9.16-9.16-9.16-9.16-9.16-9.16-9..16-9..16-9..16-9..16-9Ad

16-2 APPEN DIXAdditional Considerations for RacingWhen a plug of the correct heat range is belng used, theelectrodes will stay hot eno

APPENDIX 16-3Spark Plug ConditionCarbon Fouling Oil FoulingOverheatingNonnal OperationStandard Spark Plug ThreadsDiameter: 10 mmPitch: 1 .

16-4 APPENDIXTroubleshooting GuideCylinder, piston wornPiston ring bad (worn, weak, broken, or sticking)Piston ring/groove clearance exce

APPENDIX 16-5Engine oil viscosity too highDrive train troubleBrake draggingLubrication inadequate:Engine oil level too lowEngine oil poor

16-6 APPENDIXRear wheel misalignedPawl spring brokenShift mechanism arm brokenJumps out of gear:Shift fork wornGear groove wornGear dogs

APPENDIX 16-7General LubricationLubrication.Before lubricating each part, clean off any rusty spotswith rust remover and wipe off any

16-8 APPENDIXNut, Bolt, and Fastener TightnessStandard Torque TableThis table relating tightening torque to thread diameter,lists the ba

APPENDIX 16-9Units of LengthUnit Conversion Tablemileftin0.62143.2810.03937~Prefixes for Units:Units of Torque:N-m x 0.1020N-m x 0.7376N-

FUEL SYSTEM 2-5Throttle Grip and CablesThrottle Cable Adjustment.Check throttle grip free play.A. Accelerator CableB. AdjusterCo Locknut

2-6 FUEL SYSTEMSurge TankChoke CableSurge Tank Removal.Remove the fuel tank (this chapter)..Remove the surge tank.Choke Cable Adjustme

FUEL SYSTEM 2-7Air CleanerElement Cleaning.Remove the surge tank (see this chapter)..Take out the air cleaner element.A. PlugB. Drain H

2-8 FUEL SYSTEMCarburetors.Check the fuel level as shown.OTurn out the carburetor drain plug a few turns. Waituntil the fuel level

FUEL SYSTEM 2-9~/~Carburetor Disassembly / AssemblyFloat HeightStandard:11 :t2 mmNOTE0 Do not push the needle rod in during the float

2-10 FUEL SYSTEMFuel Pump and Filter.Turn the throttle cable lever to check that the throttlebutterfly valves move smoothly and ret

FUEL SYSTEM 2-11Fuel TankInstallation.Install the fuel tank hoses.Removal.Turn the fuel tap to the OFF position to stop the fuelflow

COOLING SYSTEM 3-1Table of Contents..3-2..3-3..3-3..3-3..3-4..3-5..3-5..3-5..3-5..3-6..3-7...3-7...3-7...3-7...3-8...3-8...3-8...3-9.3-10.3-10.3-1

3-2 COOLING SYSTEMExploded View~tJ'c:::::;,~~,"'@@)@>@CD""""'"'T1 : 2.0 N-m (0.2 kg-m. 17

GENERAL INFORMATION 1-1Table of Contents...1-2...1-4...1-5...1- 7...1-9.1-12Before Servicing Model Identification General Specifications Period

COOLING SYSTEM 3-3SpecificationsStandardItemsCoolant:TypeColorMixed ratioFreezing pointTotal amountPermanent type of antifreeze for aluminum

3-4 COOLING SYSTEMCoolant Flow ChartWhen the engine is cold, the thermostat is closed so that the coolant flow is restricted through

COOLING SYSTEM 3-5Coolant.Remove the fairings..Place a container under the engine..Remove the drain plug.Coolant Level InspectionNOTEOChec

3-6 COOLING SYSTEMPressure T esting.Remove the radiator cap, and install a cooling systempressure tester on the radiator filler neck.

COOLING SYSTEM 3-7Water PumpWater Pump Pipe Mounting BoltRadiator Hose Clamp Bolt.Apply a non-permanent locking agent to the enginesp

3-8 COOliNG SYSTEMRadiator and Radiator FanRemovalThe radiator fan is connected directly to the battery.The radiator fan may start e

COOLING SYSTEM 3-91. Pressure Tester2. Radiator Cap1. Steam Gun Running Direction.Watching the pressure gauge, pump the pressure test

3-10 COOLING SYSTEMThermostatRemoval.Remove the fairing and the side cover assembly..Drain coolant (cylinder head, cylinder)..Remove the

ENGINE TOP END 4-1Table of Contents..4-15..4-16..4-16..4-16..4-16..4-17..4-17..4-17Exploded View , , 4-2Specifications 4-4Special Tools 4-

1-2 GENERAL INFORMATIONBefore ServicingBefore starting to service a motorcycle. careful reading of the applicable section is recommended

ENGINE TOP END 4-3@~c:::c~,~e~ \~~-r c .~ " :"., ~" ~~" ~ ~~ ~~ , ~~ ~ B@ 0 ~0 ~ \\\""'>@~~~I

4-4 ENGINE TOP ENDSpecificationsItemStandardService LimitCamshaft:Cam height31 .778 -31 .918 mm31.469 -31.609 mm31 .68 mm31 .37 mm0.16 mm

ENGINE TOP END 4-5StandardService LimitItemValve/valve guide clearance(wobble method):0.031 -0.140 mm0.085- 0.180 mm0.34 mm0.41 mmInletEx

4-6 ENGINE TOP ENDSpecial ToolsCompression Gauge: 57001 -221Compression Gauge Adapter, M10 X 1.0: 57001-1317Rocker Arm Holder: 57001

ENGINE TOP END 4-7Valve Seat Cutter, 3L -<t>25: 57001-1118Valve Seat Cutter, 60. -<f>30: 57001-1123SealantValve Seat Cutter,

4-8 ENGINE TOP ENDCylinder Head CoverRemoval.Remove the following.Fuel Tank (see Fuel System chapter)Air Cleaner Housing (see Fuel Syste

ENGINE TOP END 4-9Camshaft Chain TensionerRemoval.Remove the pickup coil cover..Remove the mounting bolts and take off the camshaftch

4-10 ENGINE TOP ENDCamshaftOApply silicone sealant to the crankcase parting line andgrommet (see 4-12).OApplya non-permanent locking ag

ENGINE TOP END 4-11.Pull the tension side (exhaust side) of the chain taut toinstall the chain.OThe timing marks must be aligned

4-12 ENGINE TOP ENDNOTE0 Do not turn the camshaft when the plastigage isbetween the journal and camshaft cap.*If any clearance excee

GENERAL INFORMATION 1-3(12) Oil Seal and Grease SealReplace any oil or grease seals that were removed with new ones, as removal generally

ENGINE TOP END 4-13I ~ I-L&- <D~.;~Rocker Arm, Rocker ShaftRocker Arm and Rocker Shaft Removal.Remove the camshafts (this chapter).NO

4-14 ENGINE TOP ENDCylinder HeadCylinder Compression MeasurementRemoval.Drain coolant (see Cooling System chapter).Remove the following.Radi

ENGINE TOP END 4-15ValvesValve Clearance AdjustmentNOTE0 Valve clearance must be checked and adjusted whenthe engine is cold (at room t

4-16 ENGINE TOP END.Apply engine oil to the O-ring, install the spark plugretainer.*If the valve clearance is not within the specif

ENGINE TOP END 4-172. Too wide1 .Good1. Valve Guide Reamer: 57001-1274Valve Seat Outside Diameter.If the outside diameter of the sea

4-18 ENGINE TOP ENDNOTEODo not use a wire brush to remove the metal particlesfrom the cutter. It will take off the diamond partic

ENGINE TOP END 4-19Valve Lapping::70l'"-'-r-~-""~ccccc..iccc.-c ~~@@,3. Valve1 .Lapper2. Valve SeatMeasure Valve-to-G

4-20 ENGINE TOP ENDCylinder, PistonsCylinder Removal.Remove the following.Cylinder Head (see Cylinder Head Removal)Camshaft Chain Guide

ENGINE TOP END 4-21Piston Removal.Remove the cylinder (see this chapter)..Place a clean cloth under the pistons and remove thepiston

4-22 ENGINE TOP ENDPiston Wear.Measure the piston outside diameter 5 mm up from thebottom of the piston at a right angle to the d

1-4 GENERAL INFORMATIONModel IdentificationZX400-H2 Left Side View:ZX400-H2 Right Side View:

ENGINE TOP END 4-23Carburetor HoldersM ufflerRemoval.Remove the following.ClampsAllen Bolts.Remove the inlet pipes.Removal.Remove the foll

CLUTCH 5-1T able of Contents..5-..5-..5-..5-..5-..5...5-..5...5...5...5...5...5...5...5..5..5..5Exploded View Specifications Special Tools , Sea

5-2 CLUTCH@see 5-5nT1: 12 N-m (1.2 kg-m. 8.5 ft-Ib)T2: 9.8 N-m (1.0 kg-m. 7.0 ft-Ib)T3: 130 N-m (13.5 kg-m. 98 ft-Ib)L : Apply a non

CLUTCH 5-3SpecificationsSpecial ToolsSealant

5-4 ClUTCHClutchDue to the fiction plate wear and clutch cable stretchover a long period of use, the clutch must be adjusted inacco

CLUTCH 5-5.Turn the adjuster at the clutch lever until the free play iscorrect. At this time, check that the clutch release leverto

5-6 CLUTCHA. Cover BoltB. Holder: 57001 -1243A. Wrench.Remove the thrust washer, clutch hub, clutch cam,washer, clutch housing, needle

CLUTCH 5- 70 When install the spring plate. align the marks on the huband the plate.A. Marks9. Steel Plate10. Washer11. Hub Nut12.

5-8 ClUTCHClutch Housing Finger Inspection.Visually inspect the fingers of the clutch housing wherethe tang of the friction plates h

ENGINE LUBRICATION SYSTEM 6-1Table of Contents6-2, 6-4, 6-66-66-66- 76- 76- 76- 7, 6-86-86-86-9, 6-96-96-96-96-96-106-106-10, 6-10, 6-10,

GENERAl INFORMATION 1-5General SpecificationsItems ZX400-H2Dimensions:Overall lengthOverall widthOverall heightWheelbaseRoad clearanceSeat hei

6-2 ENGINE LUBRICATION SYSTEMExploded View@>~~~~\~<2'-@'@T1: 1.5 N-m (0.15 kg-m.13 in-Ib)T2: 4.4 N-m (0.45 kg-m. 39 in-Ib

6-4 ENGINE LUBRICATION SYSTEMEngine Oil Flow Chart@-

ENGINE LUBRICATION SYSTEM 6-51. Oil Pump Filter2. Oil Pump3. Oil Filter4. Oil Passage5. Oil Pressure Switch6. Releif Valve7. Oil Hos

6-6 ENGINE LUBRICATION SYSTEMSpecificationsSpecial ToolsSealantOil Pressure Gauge, 10 kg/cm2: 57001 -164Kawasaki Bond (Silicone Sealant):

ENGINE LUBRICATION SYSTEM 6-7Engine Oil and Oil FilterEngine Oil Change.Support the motorcycle perpendicular to the groundafter warmin

6-8 ENGINE LUBRICATION SYSTEMOil PanO Tighten the filter with the oil filter wrench to thespecified torque (see Exploded View) or t

ENGINE LUBRICATION SYSTEM 6-9Oil PumpRelief Valve, Oil Pump FilterRemoval.Remove the oil pan..Unscrew the oil pressure relief valve fro

6-10 ENGINE LUBRICATION SYSTEMOil HoseOil CoolerRemoval.Remove the following.Engine Oil (Drain, see this chapter)Lower Fairings (see Fra

Oil Pressure MeasurementOil Pressure MeasurementNOTE0 Measure the oil pressure after the engine is warmed up..Remove the following.Right

1-6 GENERAL INFORMATIONItemsZX400-H2Clutch typeTransmissionWet multi disc6-speed, constant mesh, return shift2.846 (37/13)2.055 (37/18)1.63

ENGINE REMOVAL / INSTALLATION 7-1T able of ContentsExploded View 7 -Special Tool : Engine Removal/Installation ,.., , Removal , , Inst

7-2 ENGINE REMOVAL / INSTALLATIONExploded View:.;@T1: 30 N-m (3.1 kg-m. 22 ft-Ib)T2: 36 N-m (3.7 kg-m. 27 ft-Ib)Install a shim (thickne

ENGINE REMOVAL / INSTALLATION 7-3Special ToolEngine Removal/InstallationJack: 57001 -1238~Removal.Remove the following.Fairings (see Frame

7-4 ENGINE REMOVAL / INSTALLATIONDrive Chain (see Final Drive chapter).Fill the engine with engine oil (see Engine LubricationSystem

CRANKSHAFT / TRANSMISSION 8-1Table of Contents...8-2...8-4...8-6...8-6...8-7...8-7...8-7...8-9...8-9...8-9.8-10.8-10.8-10..8-12..8-13..8-14..8-14

8-2 CRANKSHAFT / TRANSMISSIONExploded View,()@4@--@~,()'c/~~~~:--.see 8-7!~~)@~,~@CDX~IV1/'e~@0 "see 8-8@@~~~Upper Case,~dq~~C&qu

8-4 CRANKSHAFT / TRANSMISSIONSpecificationsItemStandardService LimitCrankshaft, Connecting Rods:Connecting rod big end side clearanceConnecti

CRANKSHAFT / TRANSMISSION 8-5*The bearing inserts for No.5 has no oil grooveI4.9 -5.0 mm5.05- 5.15 mm5.9 -6.0 mm6.05 -6.20 mm4.8mm5.

8-6 CRANKSHAFT / TRANSMISSIONSpecial ToolsSealantSocket Wrench, Hex 8: 57001 -1268Outside Circlip Pliers: 57001-144~Beari~g Driver Set:

GENERAl INFORMATION 1-9The table below, relating tightening torque to threaddiameter, lists the basic torque for the bolts and nuts.

CRANKSHAFT / TRANSMISSION 8-7.Apply a non-permanent locking agent to the platemounting bolt (see Exploded View). .CrankcaseCrankcase S

8-8 CRANKSHAFT / TRANSMISSIONA. Set PinB. Set Ringsc. Oil PassageA. Oil Return Hose Clamp.Apply engine oil to the transmission gears,

CRANKSHAFT / TRANSMISSION 8-9Upper CrankcaseCrankshaft/Connecting RodsCrankshaft Removal.Remove the engine..Remove the cylinder head, cyli

8-10 CRANKSHAFT / TRANSMISSIONConnecting Rod Removal.Remove the crankshaft-.Remove the connecting rods from the crankshaft.NOTE0 Mark an

CRANKSHAFT / TRANSMISSION 8-11Connecting Rod Big End BearingInsert/Crankpin ClearanceStandard: 0.031 -0.059 mmService limit: 0.10 mm* If

8-12 CRANKSHAFT I TRANSMISSIO.N*If clearance exceeds the service limit. measure thediameter of the crankshaft main journal.Crankshaft

CRANKSHAFT / TRANSMISSION 8-13.Select the proper bearing insert in accordance with thecombination of the crankcase and crankshaft cod

8-14 CRANKSHAFT / TRANSMISSIONTransmissionShift Pedal Removal.Remove the left lower fairing ( see Frame chapter) ..Mark the position of

CRANKSHAFT / TRANSMISSION 8-15View AATransmission Shaft Installation.Be careful of the following.OApply engine oil to the sliding port

8-16 CRANKSHAFT / TRANSMISSION