Manuale d’uso / di manutenzione del prodotto ZX400-H2 del fabbricante Kawasaki
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Final Drive "".
GENERAL INFORMATION 1-1 Table of Contents ...1-2 ...1-4 ...1-5 ...1- 7 ...1-9 .1-12 Before Servicing Model Identification General Specifications Periodic Maintenance Chart Torque and Locking Agent Cab.
1-2 GENERAL INFORMATION Before Servicing Before starting to service a motorcycle. careful reading of the applicable section is recommended to eliminate unnecessary work. Photographs. diagrams. notes. cautions. warnings. and detailed descriptions have been included wherever necessary.
GENERAL INFORMATION 1-3 (12) Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals. When pressing in a seal which has manufacturer's marks, press it in with the marks facing out.
1-4 GENERAL INFORMATION Model Identification ZX400-H2 Left Side View: ZX400-H2 Right Side View:.
GENERAl INFORMATION 1-5 General Specifications Items ZX400-H2 Dimensions: Overall length Overall width Overall height Wheelbase Road clearance Seat height Dry weight Curb weight: 2035 mm, (I) 2050 mm, 705 mm 1 1 25mm 1 395 mm 120 mm 765 mm 163 kg 95 kg 94 kg 16.
1-6 GENERAL INFORMATION Items ZX400-H2 Clutch type Transmission Wet multi disc 6-speed, constant mesh, return shift 2.846 (37/13) 2.055 (37/18) 1.631 (31/19) 1.380 (29/21) 1.240 (31/25) 1 .111 (30/27) 1 st 2nd 3rd 4th 5th 6th Type Gear ratios: Final drive system: Chain drive 3.
GENERAl INFORMATION 1-9 The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.
1-10 GENERAl INFORMATION Fastener Torque kg-m 0.15 1.5 0.45 1.5 1.75 1.2 1.2 Remarks ~ N-m 1.5 15 4.4 15 17 12 12 13 in-Ib 11.0 39 in-Ib 11.0 12.5 8.5 8.5 ss ss 30 36 3.1 3.7 22 27 12 8.8 8.8 20 15 9.8 12 27 1.2 0.90 0.90 2.0 1.5 8.5 78 in-Ib 78 in-Ib 14.
GENERAl INFORMATION 1-11 Fastener Torque kg-m 5.0 Remarks N-m 49 ft-Ib 36 29 19.0 7.0 16.5 39 25 9.8 23 4.0 2.6 1.0 2.3 Tie- Rod Nuts Steering: Steering Stem Head Nut Handlebar Mounting Bolts Handlebar Holder Allen Bolts Handle Holder Clamp Bolt Frame: Fairing Inner Cover Mounting Screws 31 3.
1-12 GENERAL INFORMATION Cable. Wire. and Hose Routing 1. Clutch Cable 2. Choke Cable 3. Throttle Cable 4. Speedometer Cable /Clamp Run the cable into the clamp.
GENERAL INFORMATION 1-13 1. Battery Vent Hose (Transparent) 2. Battery Vent Hose (Black) 3. Fuel Tank Breather Hose 4. Coolant Reservoir Tank Breather Hose Fuel Tank Battery / / 0-.. @ / ~ ~-L/ /~~ Coolant Reservoir Tank ..::;..,.- I /f"- , Rear Fender (front) Joint .
1-14 GENERAL INFORMATION View Looking at Front 6. Battery ( -) Lead 7. Ground Lead 8. To Ignition Coil (#1, #4) 9. To Ignition Coil (#2, #3) 1 .Main Harness 2. To Right Grip Switch 3. To Left Grip Switch 4. To Water Temperature Sensor 5. Starter Motor lead 10.
GENERAL INFORMATION 1-15 Run the lead over the fairing stay. @ 6. Ground Lead 11. Fuel Pump Lead 7. To Left Turn Signal Light 12. Pickup Coil Lead 8. Radiator Fan Switch Lead 13. Rear Brake Light Switch Lead 9. Main Harness 10. To Oil Pressure Switch, Neutral Switch and Side Stand Switch 1.
1-16 GENERAL INFORMATION To Main Harness 1 f Run the lead inside - of the water pump. "'"--' ~ 1 - t 0)- m ~ , v )~ ~ ]1 / Clamp 0-- 1.
FUEL SYSTEM 2-1 Table 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 ..
2-2 FUEL SYSTEM Exploded View.
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2-4 FUEL SYSTEM Specifications Item Standard Throttle Grip Free Play 2 -3mm 2 -3mm Choke Cable Free Play Idle Speed 1 200 :t 50 r/min (rpm) Carburetor Specifications: Make/type Synchronization vacuum .
FUEL SYSTEM 2-5 Throttle Grip and Cables Throttle Cable Adjustment .Check throttle grip free play. A. Accelerator Cable B. Adjuster Co Locknut Do Decelerator Cable .Loosen all the adjuster and slide both throttle cables at the carburetor to obtain the specified free play.
2-6 FUEL SYSTEM Surge Tank Choke Cable Surge Tank Removal .Remove the fuel tank (this chapter). .Remove the surge tank. Choke Cable Adjustment .Remove surge tank (see this chapter). .Check choke cable free play. O Remove the fuel tank (see Fuel Tank Removal).
FUEL SYSTEM 2-7 Air Cleaner Element Cleaning .Remove the surge tank (see this chapter). .Take out the air cleaner element. A. Plug B. Drain Hose Air Cleaner Housing Removal .Remove the following. Fuel Tank (see Fuel Tank Removal) Serge Tank Air Cleaner Element (see Element Cleaning) Crankcase Breather Hose .
2-8 FUEL SYSTEM Carburetors .Check the fuel level as shown. OTurn out the carburetor drain plug a few turns. Wait until the fuel level in the gauge settles. NOTE OKeeping the gauge vertical align the top line with the mark on the carburetor body right side.
FUEL SYSTEM 2-9 ~ / ~ Carburetor Disassembly / Assembly Float Height Standard: 11 :t2 mm NOTE 0 Do not push the needle rod in during the float height measurement. Carburetor Removal CD *If the needle jet is damaged, replace the carburetor .Remove the following.
2-10 FUEL SYSTEM Fuel Pump and Filter .Turn the throttle cable lever to check that the throttle butterfly valves move smoothly and return by spring tension. * If the throttle valves do not move smoothly. Replace the carburetors. .Check that the O-rings on the float bowl and pilot screws and the diaphragm on the vacuum piston are in good condition.
FUEL SYSTEM 2-11 Fuel Tank Installation .Install the fuel tank hoses. Removal .Turn the fuel tap to the OFF position to stop the fuel flow. .Remove the following. Front Seat (see Frame chapter) Side Cover Assembly Fuel Tank Mounting Bolts Fuel Tap with Fuel Hoses left installed and Fuel Hose to the carburetor removed Air Duct Clamp A.
COOLING SYSTEM 3-1 Table 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 .
3-2 COOLING SYSTEM Exploded View ~tJ' c:::::;,~ ~ , "'@ @) @ >@ CD " " " "' "' T1 : 2.0 N-m (0.2 kg-m. 17 in-Ib) T2 : 3.4 N-m (0.35 kg-m. 30 in-Ib) T3 : 7.8 N-m (0.8 kg-m. 69 in-Ib) T4 : 8.8 N-m (0.
COOLING SYSTEM 3-3 Specifications Standard Items Coolant: Type Color Mixed ratio Freezing point Total amount Permanent type of antifreeze for aluminum engines and radiators Green Soft water 50%, coolant 50% -35°C ( -31°F) 2.3 L (reservoir tank full level) 93 -123 kPa (0.
3-4 COOLING SYSTEM Coolant Flow Chart When the engine is cold, the thermostat is closed so that the coolant flow is restricted through the small hole (air hole) on the thermostat, causing the engine to warm up more quickly.
COOLING SYSTEM 3-5 Coolant .Remove the fairings. .Place a container under the engine. .Remove the drain plug. Coolant Level Inspection NOTE OCheck the level when the engine is cold (room or ambient temperature). .Check the coolant level in the reservoir tank with the motorcycle held perpendicularly.
3-6 COOLING SYSTEM Pressure T esting .Remove the radiator cap, and install a cooling system pressure tester on the radiator filler neck. NOTE 0 Wet the cap sealing surfaces with water or coolant to prevent pressure leaks. .Build up pressure in the system carefully until the pressure reaches 123 kPa (1.
COOLING SYSTEM 3-7 Water Pump Water Pump Pipe Mounting Bolt Radiator Hose Clamp Bolt .Apply a non-permanent locking agent to the engine sprocket cover bolt (one bolt only -see Final Drive chapter). .Install the water pump cover. .Fill the coolant (see Coolant Filling).
3-8 COOliNG SYSTEM Radiator and Radiator Fan Removal The radiator fan is connected directly to the battery. The radiator fan may start even if the ignition switch is off. NEVER TOUCH THE RADIATOR FAN UNTIL THE RADIATOR FAN CONNECTOR IS DISCONNECTED. TOUCHING THE FAN BEFORE THE CONNECTOR IS DISCONNECTED COULD CAUSE INJURY FROM THE FAN BLADES.
COOLING SYSTEM 3-9 1. Pressure Tester 2. Radiator Cap 1. Steam Gun Running Direction .Watching the pressure gauge, pump the pressure tester to build up the pressure. The cap must open at the relief pressure (the gauge pointer flicks down). Also the cap must hold any pressure less than the relief pressure for at least 6 seconds.
3-10 COOLING SYSTEM Thermostat Removal .Remove the fairing and the side cover assembly. .Drain coolant (cylinder head, cylinder). .Remove the following. Carburetor (see Fuel System chapter) Hose (Thermostat Housing) Mounting Bolts Water Temperature Sensor Connector .
ENGINE TOP END 4-1 Table of Contents ..4-15 ..4-16 ..4-16 ..4-16 ..4-16 ..4-17 ..4-17 ..4-17 Exploded View , , 4-2 Specifications 4-4 Special Tools 4-6 Sealant , 4- 7 Cylinder Head Cover 4-8 Removal 4.
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ENGINE TOP END 4-3 @ ~c:::c ~ , ~ e ~ ~ ~- r c .~ " :" ., ~" ~ ~" ~ ~ ~ ~ ~ , ~ ~ ~ B @ 0 ~ 0 ~ ""' >@ ~ ~ ~ I @ ~-~ "'~ e P" --, p. ~ , ~ I ~ ! @ e ) ~ t ,~ mil' J@ ~ ~oq;;::::: ~ ~ 1 A ~ / / ~ '@ CD / T1: 8.
4-4 ENGINE TOP END Specifications Item Standard Service Limit Camshaft: Cam height 31 .778 -31 .918 mm 31.469 -31.609 mm 31 .68 mm 31 .37 mm 0.16 mm 0.
ENGINE TOP END 4-5 Standard Service Limit Item Valve/valve guide clearance (wobble method): 0.031 -0.140 mm 0.085- 0.180 mm 0.34 mm 0.41 mm Inlet Exhaust Valve stem diameter 3.975 -3.990 mm 3.955 -3.970 mm 4.000 -4.012 mm 3.96 mm 3.94 mm 4.08 mm Inlet Exhaust Valve guide inside diameter ~ 57.
4-6 ENGINE TOP END Special Tools Compression Gauge: 57001 -221 Compression Gauge Adapter, M10 X 1.0: 57001-1317 Rocker Arm Holder: 57001 -1270 Valve Guide Reamer, <!>4: 57001-1274 Valve Spring C.
ENGINE TOP END 4-7 Valve Seat Cutter, 3L -<t>25: 57001-1118 Valve Seat Cutter, 60. -<f>30: 57001-1123 Sealant Valve Seat Cutter, 32.- <!>22: 57001 -1206.
4-8 ENGINE TOP END Cylinder Head Cover Removal .Remove the following. Fuel Tank (see Fuel System chapter) Air Cleaner Housing (see Fuel System chapter) Ignition Coils Throttle Cable Choke Cable Baffle Plate 1. Silicone Sealant Applied Areas A. Baffle Plate Bolt .
ENGINE TOP END 4-9 Camshaft Chain Tensioner Removal .Remove the pickup coil cover. .Remove the mounting bolts and take off the camshaft chain tensioner. A. Taper Part (Stopper) B. Push Rod .Compressing the spring against the push rod head, insert a thin wire through the hole in the push rod to keep the spring in place.
4-10 ENGINE TOP END Camshaft OApply silicone sealant to the crankcase parting line and grommet (see 4-12). OApplya non-permanent locking agent to only one bolt (see 4-12). Camshaft Removal .Remove the following. Lower Fairings (see Frame chapter) Pickup Coil Cover Damper Rubber (from Rear Cam Chain Guide) .
ENGINE TOP END 4-11 .Pull the tension side (exhaust side) of the chain taut to install the chain. OThe timing marks must be aligned with the cylinder head upper surface and positioned respectively as shown, after the camshaft chain slack is taken up by the tensioner.
4-12 ENGINE TOP END NOTE 0 Do not turn the camshaft when the plastigage is between the journal and camshaft cap. *If any clearance exceeds the service limit, measure the diameter of each camshaft journal with a micrometer. Camshaft. Camshaft Cap Clearance #1.
ENGINE TOP END 4-13 I ~ I -L&- <D~.;~ Rocker Arm, Rocker Shaft Rocker Arm and Rocker Shaft Removal .Remove the camshafts (this chapter). NOTE 0 Mark the rocker arms so they may be put back in the same position. .Remove the rocker shaft plug and rocker shaft.
4-14 ENGINE TOP END Cylinder Head Cylinder Compression Measurement Removal .Drain coolant (see Cooling System chapter) .Remove the following. Radiator (see Cooling System chapter) Muffler Camshafts (see this chapter) Oil Hose (Cylinder Head) Engine Mounting Bracket Bolts, Nuts (Cylinder Head) .
ENGINE TOP END 4-15 Valves Valve Clearance Adjustment NOTE 0 Valve clearance must be checked and adjusted when the engine is cold (at room temperature). .Remove the following. Cylinder Head Cover Spark Plug Retainer .Using a thickness gauge, measure the valve clearance between the rocker arm and the cam.
4-16 ENGINE TOP END .Apply engine oil to the O-ring, install the spark plug retainer. *If the valve clearance is not within the specified range, first record the clearance, and then adjust it. .To change the valve clearance, replace the shim with one of a different thickness.
ENGINE TOP END 4-17 2. Too wide 1 .Good 1. Valve Guide Reamer: 57001-1274 Valve Seat Outside Diameter .If the outside diameter of the seating pattern on the valve seat is too large or too small, repair the valve seat. 4. Uneven 3. Too narrow 21.5 ~ 21.
4-18 ENGINE TOP END NOTE ODo not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles. 4. Setting the valve seat cutter holder in position, operate the cutter in one hand. Do not apply too much force to the diamond portion.
ENGINE TOP END 4-19 Valve Lapping ::70 l' "-' -r-~ -""~ccccc..iccc.-c ~~ @ @, 3. Valve 1 .Lapper 2. Valve Seat Measure Valve-to-Guide Clearance (Wobble Method) If a small bore gauge is not available, inspect the valve guide wear by measuring the valve to valve guide clearance with the wobble method as indicated below.
4-20 ENGINE TOP END Cylinder, Pistons Cylinder Removal .Remove the following. Cylinder Head (see Cylinder Head Removal) Camshaft Chain Guide (exhaust side) Water Pipe .Remove the cylinder. Cylinder Installation .Install the new cylinder gasket. .Apply engine oil to the cylinder bore.
ENGINE TOP END 4-21 Piston Removal .Remove the cylinder (see this chapter). .Place a clean cloth under the pistons and remove the piston pin snap rings from the outside of each piston. .Using the piston pin puller assembly (special tool), remove the piston pins.
4-22 ENGINE TOP END Piston Wear .Measure the piston outside diameter 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin. Piston Ring End Gap .Place the piston ring inside the cylinder, using the piston to locate the ring squarely in place.
ENGINE TOP END 4-23 Carburetor Holders M uffler Removal .Remove the following. Clamps Allen Bolts .Remove the inlet pipes. Removal .Remove the following. Lower Fairing Radiator {Do not remove the hoses and not drain coolant.) .Remove the nuts and take off the exhaust pipe holders.
CLUTCH 5-1 T able of Contents ..5- ..5- ..5- ..5- ..5- ..5. ..5- ..5. ..5. ..5. ..5. ..5. ..5. ..5. ..5 ..5 ..5 ..5 Exploded View Specifications Special Tools , Sealant , Clutch. , Clutch Adjustment Check Clutch Adjustment , Clutch Release Lever Removal Clutch Release Lever Installation Notes.
5-2 CLUTCH @ see 5-5 n T1: 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-permanent locking agent to the threads. M: Apply a thin coat of a molybdenum disulfide grease. 55: Apply silicone sealant to the threads.
CLUTCH 5-3 Specifications Special Tools Sealant.
5-4 ClUTCH Clutch Due to the fiction plate wear and clutch cable stretch over a long period of use, the clutch must be adjusted in accordance with the Periodic Maintenance Chart. A. Fairing Mounting Screws B. Fairing Mounting Bolts Clutch Adjustment Check .
CLUTCH 5-5 .Turn the adjuster at the clutch lever until the free play is correct. At this time, check that the clutch release lever to clutch cable angle is 80 -gOD. Clutch Cover Removal .Drain the engine oil (see Engine Oil Change in Engine Lubrication System chapter).
5-6 CLUTCH A. Cover Bolt B. Holder: 57001 -1243 A. Wrench .Remove the thrust washer, clutch hub, clutch cam, washer, clutch housing, needle bearing, collar, and spacer. Clutch Installation Notes .Clutch installation is the reverse of removal. attention to the following items.
CLUTCH 5- 7 0 When install the spring plate. align the marks on the hub and the plate. A. Marks 9. Steel Plate 10. Washer 11. Hub Nut 12. Pusher 13. Bearing 14. Spring Plate 15. Clutch Spring 16. Retainer O Tighten the clutch spring bolts to the specified torque (see Exploded View).
5-8 ClUTCH Clutch Housing Finger Inspection .Visually inspect the fingers of the clutch housing where the tang of the friction plates hit them. * If they are badly worn or if there are grooves cut where the tang hit, replace the housing. Also, replace the friction plates if their tangs are damaged.
ENGINE LUBRICATION SYSTEM 6-1 Table of Contents 6-2 , 6-4 , 6-6 6-6 6-6 6- 7 6- 7 6- 7 6- 7 , 6-8 6-8 6-8 6-9 , 6-9 6-9 6-9 6-9 6-9 6-10 6-10 6-10 , 6-10 , 6-10 , 6-10 6-11 6-11 Exploded View Engine O.
6-2 ENGINE LUBRICATION SYSTEM Exploded 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) T3: 9.8 N-m (1.0 kg-m. 7.0 ft-Ib) T4: 12 N-m (1.2 kg-m. 8.5 ft-Ib) T5: 15 N-m (1.5 kg-m. 11.0 ft-Ib) T6: 17 N-m (1.
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6-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart @-.
ENGINE LUBRICATION SYSTEM 6-5 1. Oil Pump Filter 2. Oil Pump 3. Oil Filter 4. Oil Passage 5. Oil Pressure Switch 6. Releif Valve 7. Oil Hose 8. Camshaft Bracket 9. Camshaft 10. Rocker Arm 11. Oil Return Passage 12. Oil Pipe (to Mission) 13. Oil Pipe (to Output Shaft) 14.
6-6 ENGINE LUBRICATION SYSTEM Specifications Special Tools Sealant Oil Pressure Gauge, 10 kg/cm2: 57001 -164 Kawasaki Bond (Silicone Sealant): 56019-120 ~~ Oil Pressure Gauge Adapter.
ENGINE LUBRICATION SYSTEM 6-7 Engine Oil and Oil Filter Engine Oil Change .Support the motorcycle perpendicular to the ground after warming up the engine. .Remove the engine drain plug to drain the oil. Oil Level Inspection .Support the motorcycle perpendicular to the ground.
6-8 ENGINE LUBRICATION SYSTEM Oil Pan O Tighten the filter with the oil filter wrench to the specified torque (see Exploded View) or tighten it with hands about * turns after gasket contacts the mounting surface of engine. O Pour in the specified type and amount of oil.
ENGINE LUBRICATION SYSTEM 6-9 Oil Pump Relief Valve, Oil Pump Filter Removal .Remove the oil pan. .Unscrew the oil pressure relief valve from the engine. .Pullout the oil pump filter and the oil pipe. Removal .Remove the following. Clutch (see Clutch chapter) Circlip Oil Pump Gear Oil Pump Cover A.
6-10 ENGINE LUBRICATION SYSTEM Oil Hose Oil Cooler Removal .Remove the following. Engine Oil (Drain, see this chapter) Lower Fairings (see Frame chapter) Muffler (see Engine Top chapter) Oil Cooler Pipe Fitting Bolts Oil Cooler Mounting Bolts Removal .
Oil Pressure Measurement Oil Pressure Measurement NOTE 0 Measure the oil pressure after the engine is warmed up. .Remove the following. Right Lower Fairing (see Frame chapter) Oil Passage Plug .Attach the oil pressure gauge and adapter (special tools) to the plug hole.
ENGINE REMOVAL / INSTALLATION 7-1 T able of Contents Exploded View 7 - Special Tool : Engine Removal/Installation ,.., , Removal , , Installation 7 -4.
7-2 ENGINE REMOVAL / INSTALLATION Exploded 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 (thickness 0.5 mm) between the lower part of the crankcase and the frame bracket.
ENGINE REMOVAL / INSTALLATION 7-3 Special Tool Engine Removal/Installation Jack: 57001 -1238 ~ Removal .Remove the following. Fairings (see Frame chapter) Engine Oil ( Drain, see Engine Lubrication Sy.
7-4 ENGINE REMOVAL / INSTALLATION Drive Chain (see Final Drive chapter) .Fill the engine with engine oil (see Engine Lubrication System chapter). .Fill the engine with coolant and bleed the air from the cooling system (see Cooling System chapter). .Adjust the carburetor synchronization and idling.
CRANKSHAFT / TRANSMISSION 8-1 Table 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 .
8-2 CRANKSHAFT / TRANSMISSION Exploded View ,() @4 @--@ ~ , ()' c/~~ ~~ :--. see 8-7 ! ~ ~ )@ ~ ,~ @ CD X ~ IV 1/' e ~ @ 0 " see 8-8 @@ ~ ~ ~ Upper Case , ~ d q ~ ~C" @6mm I I SDID @-, 8mm -@ d T1: 8.8 N-m (0.9 kg-m. 78 in-Ib) T2: 9.
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8-4 CRANKSHAFT / TRANSMISSION Specifications Item Standard Service Limit Crankshaft, Connecting Rods: Connecting rod big end side clearance Connecting rod big end bearing insert/crankpin clearance Crankpin diameter: Marking None o Connecting rod big end bore diameter: Marking None 0 Connecting rod big end bearing insert thickness: Blue 1 .
CRANKSHAFT / TRANSMISSION 8-5 *The bearing inserts for No.5 has no oil groove I 4.9 -5.0 mm 5.05- 5.15 mm 5.9 -6.0 mm 6.05 -6.20 mm 4.8mm 5.3mm 5.8mm 6.
8-6 CRANKSHAFT / TRANSMISSION Special Tools Sealant Socket Wrench, Hex 8: 57001 -1268 Outside Circlip Pliers: 57001-144 ~ Beari~g Driver Set: 57001 -1129.
CRANKSHAFT / TRANSMISSION 8-7 .Apply a non-permanent locking agent to the plate mounting bolt (see Exploded View). . Crankcase Crankcase Splitting .Remove the engine (see Engine Removal/Installation chapter) . .Set the engine on a clean surface and hold the engine steady while parts are being removed.
8-8 CRANKSHAFT / TRANSMISSION A. Set Pin B. Set Rings c. Oil Passage A. Oil Return Hose Clamp .Apply engine oil to the transmission gears, ball bearings, shift drum, and crankshaft main bearing inserts. .Apply liquid gasket -black and silicone sealant as shown in the figure below.
CRANKSHAFT / TRANSMISSION 8-9 Upper Crankcase Crankshaft/Connecting Rods Crankshaft Removal .Remove the engine. .Remove the cylinder head, cylinder and pistons. .Split the crankcase (see Crankcase Splitting). .Take the crankshaft out of the upper crankcase.
8-10 CRANKSHAFT / TRANSMISSION Connecting Rod Removal .Remove the crankshaft- .Remove the connecting rods from the crankshaft. NOTE 0 Mark and record the locations of the connecting rods and their big end caps so that they can be reassembled in their original positions.
CRANKSHAFT / TRANSMISSION 8-11 Connecting Rod Big End Bearing Insert/Crankpin Clearance Standard: 0.031 -0.059 mm Service limit: 0.10 mm * If clearance is within the standard, no bearing replace- ment is required. *If clearance is between 0.059 mm and the service limit (0.
8-12 CRANKSHAFT I TRANSMISSIO.N *If clearance exceeds the service limit. measure the diameter of the crankshaft main journal. Crankshaft Main Journal Diameter Standard: 29.984 -30.000 mm Service Limit: 29.96 mm * If any journal has worn past the service limit.
CRANKSHAFT / TRANSMISSION 8-13 .Select the proper bearing insert in accordance with the combination of the crankcase and crankshaft coding. .Install the new inserts in the crankcase halves and check insert/journal clearance with plastigage. Crankshaft Side Clearance .
8-14 CRANKSHAFT / TRANSMISSION Transmission Shift Pedal Removal .Remove the left lower fairing ( see Frame chapter) . .Mark the position of the shift lever on the shift shaft so that it can be installed later in the same position. .Remove the shift lever and shift pedal.
CRANKSHAFT / TRANSMISSION 8-15 View AA Transmission Shaft Installation .Be careful of the following. OApply engine oil to the sliding portion of the gears and bearings. O Check to see that the set pins and set rings are in place. O Install the drive shaft and output shaft into the upper crankcase half.
8-16 CRANKSHAFT / TRANSMISSION.
CRANKSHAFT / TRANSMISSION 8-17 Shift Drum and Fork Removal .Remove the following. Lower Crankcase Half (see Crankcase Splitting) External Shift Mechanism (see this chapter) Shift Drum Bearing Retainer Bolt Shift Drum Disassembly .Remove the shift drum (see this chapter).
WHEELS / TIRES 9-1 Table of Contents 9-2 9-3 9-4 9-5 9-5 9-5 9-6 9-6 9-6 9-7 9-8 9-8 9-8 9-8 9-8 9-9 9-11 9-11 9-11 9-11 9-11 9-11 9-11 ..~ Exploded View Specifications ,.
9-2 WHEELS / TIRES Exploded View / 165J @ @ ~ ~ ~ @~ ~ ~ ~ @" @. ~ I:[:;l:~ !fi;~ T1:11 N-m(11.0kg-m,80ft-Ib) G : Apply grease..
WHEELS / TIRES 9-3 Specifications Service Limit Standard Item Wheels: Rim runout (with tire installed) Axial Radial Axle runout/1 00 mm 0.5mm 0.8mm 0.2 mm Under 0.05 mm Tires: Air pressure (when cold) Front Rear Tread Depth: Front Rear 225 kPa (2.25 kg/cm2, 32 psi) 250 kPa (2.
9-4 WHEELS / TIRES Special Tools Bearing Driver Set: 57001 -1129 Bearing Remover Head. <1>15 x <1>17: 57001 -1267 ~ Bearing Remover Shaft: 57001 -1265.
WHEELS / TIRES 9-5 Wheels (Rims) Front Wheel Removal .Remove the following. Lower Fairings (see Frame chapter) Speedometer Cable Lower End Right and Left Brake Calipers B. Jack: 57001 -1238 A. Jack or Stand .Pull out the axle to the right and drop the front wheel out of the forks.
9-6 WHEELS / TIRES ~ A. Rear Wheel B. Rear Caliper Bracket 1 .Housing Stop 2. Fork Leg Stop 3. Front OFit the collar in the right side of the hub. .Apply grease to the speedometer gear and hub grease seal. .Tighten the following fasteners to the specified torque (see Exploded View).
WHEELS / TIRES 9-7 Rim Runout O Check that the blade and weight seat fully on the rim flange, and that the clip is hooked over the rim ridge and reaches rim flat portion. If the balance weight has any play on the rim flange. the blade and/or clip have been stretched.
9-8 WHEELS / TIRES Tires Tire Air Pressure Inspection Balance Weight Removal (a) When the tire is not on the rim. .Push the blade portion toward the outside with a regular tip screw driver, and slip the weight off the rim flange- .Discard the used balance weight.
WHEELS / TIRES 9-9 2. Valve Stem 1. Chalk Mark or Yellow Mark .Lubricate the tire beads and rim flanges on both sides with a soap and water solution or rubber lubricant. This helps the tire beads slip off the rim flanges. 1 .Plastic Cap 2. Valve Core 3.
9-10 WHEELS I TIRES .After the tire beads seat in the rim flanges, check for air leaks. Inflate the tire slightly above standard inflation. Use a soap and water solution or submerge the tire, and check for bubbles that would indicate leakage. .Adjust the air pressure to the specified pressure (see Tire Inspection).
WHEELS / TIRES 9-11 Speedometer Gear Housing Hub Bearings Disassembly and Assembly NOTE Olt is recommended that the assembly be replaced rather than attempting to repair the components. Removal .Remove the following. Wheel (see this chapter) Oil Seals and Circlips .
FINAL DRIVE 10-1 Table 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 .10-7 Exploded View Specifications Special Tools Drive Chain Drive Chain Slack Adjustment Wheel Alignment Adjustment . Drive Chain Wear Inspection.
10-2 FINAL DRIVE Exploded 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 locking agent to the threads.
FINAL DRIVE 10-3 Specifications Special Tools Jack: 57001 -1238 ~ Inside Circlip Pliers: 57001-143 ~ ~ ~ I I.
10-4 FINAL DRIVE Drive Chain Drive Chain Slack Adjustment .Set the motorcycle up on its side stand and check that the chain slack is within the standard value. Drive Chain Slack Standard: Service Limit: 20 -35 mm (35mm is best) 20-40mm A. Locknut B. Adjuster C.
FINAL DRIVE 10-5 I,,~ Cj) I !- '- -. ~ ." "' . Oil Applied Areas 1st 21st 1 .Weight 2. Straight Part 3. Ruler 4. Measure this length. Drive Chain 20-link length Standard: 317.5 -318.2 mm Service limit: 323 mm Drive Chain Removal .Remove the following.
10-6 FI NAl DRIVE Sprocket, Coupling Engine Sprocket Removal .Loosen the drive chain (see Drive Chain Slack Adjust- ment) . .Remove the following. Left Lower Fairing (see Frame chapter) Shift Pedal Engine Sprocket Cover C. Engine Sprocket Cover A. Bolts B.
FINAL DRIVE 10-7 Rear Sprocket Removal .Remove the rear wheel (see Wheels/Tires chapter) NOTE OSprocket wear is exaggerated for illustration. Sprocket Teeth Worn T ooth (Engine Sprocket) Worn Tooth (Rear Sprocket) .Pullout the rear wheel coupling from the rear wheel.
BRAKES 11-1 Table 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 .11-10 .11-11 .11-11 .11-11 .11-12 .11-12 .11-13 .11-13 .11-13 .11-13 .11-13 .11-13 .11-14 .
11-2 BRAKES Exploded 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: 5.9 N-m (0.6 kg-m. 52 in-Ib) T5: 7.8 N-m (0.8 kg-m. 69 in-Ib) T6: 18 N-m (1.8 kg-m.13.0 ft-Ib) T7: 21 N-m (2.
BRAKES 11-3 f ~ '@ ~/V ~ G : Apply grease. M : Apply molybdenum disulfide grease..
11-4 BRAKES Specifications Item Standard Service limit Brake Fluid: Grade Brand (recommendedj D.O.T.3 Atlas Extra Heavy Duty Shell Super Heavy Duty Texaco Super Heavy Duty Wagner Lockheed Heavy Duty C.
BRAKES 11-5 Brake Fluid Brake Fluid Requirement: Recommended fluids are given in the table below. If none of the recommended brake fluids are available, use extra heavy-duty brake fluid only from a container marked D.
11 -6 B RAKES When working with the disc brake, observe the precautions listed below. Bleeding the Brake Line The brake fluid has a very low compression coefficient so that almost all the movement of the brake lever or pedal is transmitted directly to the caliper for braking action.
BRAKES 11-7 Brake Pedal Brake Pedal Position Adjustment .Check that the brake pedal is in the correct position. Pedal Position Standard: About 43 mm below from center of brake pedal shaft 1. Hold the brake applied. 2. Quickly open and close the valve.
11-8 BRAKES Calipers Rear Brake Light Switch Adjustment .Check the operation of the rear brake light switch by depressing the brake pedal. The brake light should go on after about 10 mm of pedal travel. Front Caliper Removal .Remove the following. Banjo Bolt (at the caliper) Caliper Mounting Bolts .
BRAKES 11-9 C. Caliper Mounting Bolts A. Caliper Assembly Bolts A. Banjo Bolt B. Caliper Assembly Bolts .Remove the piston insulator and the O-rings. .Using compressed air, remove the pistons. One way to remove the pistons is as follows. O Install a wooden board more than 10 mm thick and a rubber gasket on the caliper half as shown.
11-10 BRAKES O Pullout the pistons by hand. A. Rear Caliper B. Apply compressed air. Assembly Notes .Apply brake fluid to the cylinders, pistons, and fluid seals, and push the pistons into the cylinders by hand. Take care that neither the cylinder nor the piston skirt get scratched.
BRAKES 11-11 Brake Pads Front Brake Pad Removal .Remove the following. Pad Spring Clip Pad Pin A. Piston Insulators B. O-Rings .Tighten the caliper assembly bolts to the specified torque (see Exploded View). A. Pad Spring A. Pad Pin B. Clip .Remove the brake pads.
11-12 BRAKES Lining Wear .For front caliper pad inspection, remove the pad spring (see Front Caliper Removal). .For rear caliper pad inspection, remove the rear caliper (see this chapter). .Remove the pad cover. *If the lining thickness of either pad is less than the service limit replace both pads in the caliper as a set.
BRAKES 11-13 Master Cylinders Rear Master Cylinder Installation Notes .Use a new flat washer on each side of the brake hose fitting. .Tighten the banjo bolts to the specified torque (see Exploded View) . .Tighten the rear master cylinder mounting bolts (2) to the specified torque (see Exploded View).
11-14 BRAKES Brake Discs Assembly .Before assembly, clean all parts including the master cylinder with brake fluid or alcohol. .Apply brake fluid to the removed parts and to the inner wall of the cylinder. I nsta!lation .Install the brake disc on the wheel so that the rotation mark aligns with the tire rotation.
BRAKES 11-15 Disc Runout Standard: Service Limit: Under 0.2 mm 0.3mm.
SUSPENSION 12-1 Table 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 .12-13 .12-13 .12-13 .12-13 .12-14 .12-14 .12-14 .12-14 .12-14 .12-14 .12-14 Exploded View Specifications Special Tools Front Fork Rebound Damping Force Adjustment .
12-2 SUSPENSION Exploded View @ ~ ~ --<-;: 0- I """'I I : 0 ~ ~ ~ ~ ~ ~ I "! ~ @ I~ l ~ ~ .U a I I O I I /1= i ! I I ! I f I I I I! I j I [ I ~ I . @ I i I ~~ ~ " @ ~ ~ ~ ~ ~~ ) ~ <::1 @ ~ I ~ 1"'--- ~ ~? ~ ~ T1: 15 N-m (1.
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12-4 SUSPENSION Specifications Item Standard Service Limit Front Fork: Rebound damping setting Spring preload setting 6th click from fully counterclockwise position 1/4 turn out position from fully counterclockwise position SAE 5W 355 mL 421 :t4 ml 94 :f:2 mm below from top of inner tube 311 .
SUSPENSION 12-5 Special Tools Oil Syringe: 57001 -1290 Steering Stem Nut Wrench: 57001 -1100 Fork Cylinder Holder: 57001-1297 Bearing Driver Set: 57001 -1129 Fork Outer Tube Weight: 57001 -1218 Jack: 57001 -1238 /' "' , ,.
12-6 SUSPENSION Front Fork Rebound Damping Force Adjustment .To adjust the rebound damping, turn the rebound damping adjuster until you feel a click. A. Preload Adjuster OThe standard adjuster setting for the average-build rider of 68 kg (150 Ib) with no passenger and no accessories is 14 mm as shown.
SUSPENSION 12-7 NOTE 0 Measure the fork oi!!evel compressing the outer tube and piston rod down with the push rod installed. OSet the oil syringe stopper so that its lower side shows the oil level distance specified. Fork Oil Change .Remove the following.
12-8 SUSPENSION Removal .Remove the following. Lower Fairing Front Wheel Front Fender Mounting Bolts and Screws Fork Clamp Bolts (upper and lower, loosen) Handle Holder Clamp Bolts (loosen) A. Outer Tube B. Steering Stem Head .Tighten the following fasteners to the specified torque (see Exploded View).
SUSPENSION 12-9 Push Rod Piston Rod Nut A. Push Rod B. Piston Rod c. Piston Rod Nut .Pour the fork oil into a container. .Remove the following from the outer tube. Dust Seal Circlip 1. Inner Tube 2. Weight: 57001-1218 3. Outer Tube 4. Pull down. OThe oil seal, washer, and guide bushes come off with the inner tube.
12-10 SUSPENSION A. 12 mm or more B. Rod Nut c. Piston Rod Assembly .Replace the bottom Allen bolt gasket with new one. .Replace the following with new ones whenever they have removed from inner tube. Oil Seal Dust Seal .Visually inspect the following, and replace them if necessary.
SUSPENSION 12-11 Rear Shock Absorber Rebound Damping Force Adjustment The rebound damping force adjuster at the lower end of the rear shock absorber has 4 positions so that the rebound damping force can be adjusted for different road and loading conditions.
12-12 SUSPENSION 1 .Banjo Bolt A. Rear Shock Absorber Mounting Bolt, Nut (upper) Scrapping Since the rear shock absorber contains nitrogen gas. do not incinerate the rear shock absorber without first releasing the gas or it may explode. Before a rear shock absorber is scrapped.
SUSPENSION 12-13 Swing Arm Swing Arm Sleeve Inspection * If there is visible damage, replace the sleeve, the ball bearing, and all the needle bearings as a set. Removal .Remove the following. Rear Wheel (see Wheels/Tires chapter) Shock Absorber Mounting Bolt (lower) Tie-Rod Bolts (upper) Swing Arm Shaft A.
12-14 SUSPENSION Tie-Rod, Rocker Arm Tie-Rod Removal .Remove the following. Lower Fairings (see Frame chapter) Rocker Arm (see Rear Shock Removal) Lower and Upper Tie-Rod Bolts A. Rocker Arm Grease Nipples Rocker Arm Removal .The rocker arm is removed during the rear shock removal.
SUSPENSION 12-15 Tie-Rod, Rocker Arm Sleeve Inspection *If there is visible damage, replace the sleeve and needle bearing(s) as a set..
STEERING 13-1 Table 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- 7 Exploded View Special Tools Steering , Adjustment , Steering Stem Removal , Installation Steering Stem Bearing Bearing Lubrication Bearing Wear, Damage Stem Cap Deterioration, Damage.
13-2 STEERING Exploded View r ~ e II r@ @, ~ ~ £ @"' @ @ --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 (4.0 kg-m. 29 ft-Ib) T4: 25 N-m (2.6 kg-m. 19.0 ft-Ib) G : Apply grease. ~ )- :(.:.n.. ?j) y ~ .
STEERING 13-3 Special Tools Head Pipe Outer Race Driver: 57001 -1106 (?]}) Steering Stem N ut Wrench: 57001 -1100 Bearing Puller Stud: 57001 -1190 Head Pipe Outer Race Press Shaft: 57001-1075 ~ ~.
13-4 STEERING Steering Steering Stem Head Nut Front Fork Lower Clamp Bolts .Check the steering again. * If the steering is still too tight or too loose, repeat the adjustment. Adjustment .Check the steering. O Lift the front wheel off the ground using the jack ( special tool: 57001 -1238, see Wheels/Tires chapter) .
STEERING 13-5 Steeri ng Stem Removal .Remove the following parts. Surge Tank (see Fuel System chapter) Upper and Lower Fairings (see Frame chapter) Front Fork Legs (see Suspension chapter) Brake Hose Joint Steering Stem Head Nut Stem Head. Handlebar, Handle Holder .
13-6 STEERING .1 Grease Seal OApply grease to the lower tapered roller bearing, and drive it onto the steering stem using the stem bearing driver and adapter (special tools: 57001-137 and 57001 -1092) . 1. Upper Bearing 2. O-ring 3. Grease Seal 4. Stem Locknut 5.
STEERING 13-7 Choke Cables Clutch Front Brake Steering Stem Bearing Bearing Lubrication .Perform the following. O Remove the steering stem. O Using a high-flash point solvent. wash the upper and lower tapered roller bearings in the cages. O Wipe the upper and lower outer races.
FRAME 14-1 Table of Contents .14-2 .14-5 .14-5 .14-5 .14-5 .14-5 .14-6 .14-6 .14-6 .14-6 .14-6 Exploded View Seats Front Seat Removal Front Seat Installation... Rear Seat Removal Rear Seat Installation Side Covers Side Cover Removal Fairings Upper Fairing Removal.
14-2 FRAME Exploded View ~ l Apply a non-permanent locking agent to the threads..
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FRAME 14-5 Seats Front Seat Removal .Remove the front seat mounting bolt, move it upward and slide it forward. A. Seat Lock B. Seat Mounting Belt Rear Seat Installation .Install the seat mounting belt. .Slip the hooks of the rear seat under the brace on the frame and put the stoppers of the seat into the ho)es in the frames.
14-6 FRAME Side Covers Fairings Upper Fairing Removal .Remove the following in the order listed. Rear View Mirror Nuts Upper Fairing Mounting Bolts and Screws Air Duct Clamps ( Loosen ) Turn Signal Connectors Side Cover Removal .Remove the following. Front Seat Rear Seat Seat Pad Left and Right Cover Clamp Screws Side Cover Mounting Screws A.
FRAME 14-7 NOTE 0 Remove the lower fairings as assembly..
ELECTRICAL SYSTEM 15-1 T 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 .15-28 .15-29 .15-29 .15-29 .15-30 .15-31 .15-31 .1 5-31 .15-31 .15-31 ..15-2 ...15-3 ...15-4 .
15-2 ELECTRICAL SYSTEM O Color Codes: BK BL BR CH DG G GY LB LG O p PU R W Y Precautions Black Blue Brown Chocolate Dark green Green Gray Light blue Light green Orange Pink Purple Red White Yellow There are a number of important precautions that are musts when servicing electrical systems.
ELECTRICAL SYSTEM 15-3 Wiring Diagram (ZX400-H2) ~ ~ ~ c ., .i~ §; I ~ m w~ IC A ":=0 ~~ ** ~.~ ..L- ~ ,.,. ~ .i " A S ~ M ~I r "~ ~ - 1 1t :~ ~ ...:J i A~."~ I' . '01 ...10 ~ "".'yOll"~ ,.- ~ '01 'yOllll.
15-4 ELECTRICAL SYSTEM Parts location 1. Headlight Unit 2. Meter Unit 3. Starter Motor 4. Tail/Brake Light 5. Licence Light 6. Fan Switch 7. Alternator 8. Oil Pressure Switch 9. Neutral Switch 10. Side Stand Switch 11. Turn Signal Light 12. Fuel Pump 13.
ELECTRICAL SYSTEM 15-5 Exploded 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-Ib) T4: 13 N-m (1.3 kg-m, 113 in-Ib) T5: 25 N-m (2.5 kg-m, 18 ft-Ib) T6: 34 N-m (3.5 kg-m, 25 ft-Ib) T7: 78 N-m (8.
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15-8 ELECTRICAL SYSTEM Specifications Item Standard Service Limit 12V10Ah 1.280 @20°C (68°F) Battery: Type Specific gravity Alternator: Charging voltage Output voltage Stator coil resistance 14.5 V Night @4000 r/min (rpm) No less than 43 V @4000 r/min (rpm) 0.
ELECTRICAL SYSTEM 15-9 Special T 0015 Hand Tester: 57001-983 Flywheel Holder: 57001 -1313 Coil Tester: 57001 -1242 Spark Plug Wrench, Hex 16: 57001 -1262 ~ Socket Wrench, Hex 8: 57001 -1268 Sealant Ja.
15-10 ELECTRICAL SYSTEM *If the specific gravity is below 1.20 (charge 60%), the battery needs to be charged. Battery Initial Charging .Remove the rear and front seats (see Frame chapter) and take out the battery. Electrolyte Level Inspection .The electrolyte level should be between the upper and the lower level lines.
ELECTRICAL SYSTEM 15-11 Charging System Alternator Cover Removal .Remove the lower fairing. .Set a suitable container under the engine. .Remove the alternator cover bolts, using the socket wrench (special tool: 57001-1268). A. Alternator Cover Bolt .Remove the alternator cover.
15-12 ELECTRICAL SYSTEM A. Silicone Sealant Applied Area A. Flywheel Holder: 57001 -1 31 3 C. Rotor Bolt B. Rotor .Apply silicone sealant to the left inner cover bolt. .Threads the rotor puller (special tool) and the rotor puller (special tool) onto the alternator rotor.
ELECTRICAL SYSTEM 15-13 Alternator Rotor Cleaning Area A. Holding Plate B. Grommets c. Mounting Bolts D. Stator 1. The tapered portion of the crankshaft. 2. The alternator rotor bolt and the threads in the crankshaft. 3. The tapered portion of the alternator rotor.
15-14 ELECTRICAL SYSTEM 57001-983) Connect the hand tester (special tool: as shown in table. Note the readings (total 3 measurement) Rectifier Inspection .Check the rectifier resistance as follows. .Remove the regulator/rectifier and disconnect the connector 2 (see Charging System Wiring Diagram).
ELECTRICAL SYSTEM 15-15 .Connect the brown lead terminal to the other battery ( + ) terminal and connect the black/yellow lead terminal to the battery ( -) terminal momentarily. At this time the bulb should not be lit. 4. Y1 Lead Terminal 5. Y2 Lead Terminal 6.
15-16 ELECTRICAL SYSTEM .Repeat the above three steps for other two yellow leads (in connector 2 which leads to the regulator/rectifier) ) . *Replace the regulator/rectifier if the bulb does not light as described above. Ignition System NOTE 0 The above test is not foolproof.
ELECTRICAL SYSTEM 15-17 Pickup Coil Resistance (x 100 0) 355 -5350 (BK, y lead) *If the distance reading is less than the specified value, the ignition coil or spark plug caps are defective. .Using the highest resistance range of the ohmmeter, measure the resistance between the pickup coil leads and chassis ground.
15-18 ELECTRICAL SYSTEM .Check the spark plug leads for visible damage. *If any spark plug lead is damaged, replace the coil Ignition System Wiring Diagram 1. IC Igniter 2. 6-pin Connector 3. 4-pin Connector 4. 2-pin Connector 5. Pickup Coil (#1, #4 Cylinder) 6.
ELECTRICAL SYSTEM 15-19 Spark Plug Removal .Remove the following. Surge Tank (see Fuel System chapter) Spark Plug Caps .Remove the spark plugs with the box wrench in the tool kit (PIN: 92110-1146) or the spark plug wrench (special tool: 57001-1262). <D ~ -@ rJ5' ~ 3.
15-20 ELECTRICAL SYSTEM IC Igniter Internal Resistance Range: kQ Electric Starter System Starter Motor Removal .Remove the fuel tank (see Fuel System chapter). .Remove the terminal nut of starter motor wiring and take out the mounting bolts. O Using the socket wrench (special tool: 57001 -1268) makes work easy.
ELECTRICAL SYSTEM 15-21 Starter Motor Assembly Note .Inspect the O-rings if it is not damaged. .Install the brushes and springs into the end cover holder. OClamp the brush leads with clips on the end cover and fix the springs. NOTE OBe careful not to damage the leads and O-rings.
15-22 ELECTRICAL SYSTEM 2. Shaft 1. Segment 1. Commutator 2. Emery Cloth NOTE OEven if the foregoing checks show the armature to be good. it may be defective in some manner not readily detectable with an ohmmeter. If all other starter motor and starter motor circuit components check good.
ELECTRICAL SYSTEM 15-23 Brush Plate and Terminal Bolt Inspection .Using the x 1 .0 ohmmeter range, measure the resist- ance as shown. between terminal bolt and brush plate between terminal bolt and ( -) brush between terminal bolt and end cover * If there is any reading, the brush holder assembly and/or terminal bolt assembly have a short.
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ELECTRICAL SYSTEM 15-25 Lighting System The headlight beam is adjustable both horizontally and vertically. Headlight aiming must be correctly adjusted both for your safety as well as that of oncoming drivers. In most areas it is illegal to ride with an improperly adjusted headlight.
15-26 ELECTRICAL SYSTEM A. Pin Closest to Base. 1 .Dust Cover 2. Headlight Bulb .Insert the socket by aligning the tangs with the catches in the housing so that the triangular mark points left, and turn it clockwise. .Check the headlight aim after installation.
ELECTRICAL SYSTEM 15-27 Radiator Fan System Fan System Circuit Inspection .Remove the left lower fairing and disconnect the leads from the radiator fan switch. A. Turn Signal Relay .Check the condition or the relay for the following troubles. A. Fan Switch Terminals .
15-28 ELECTRICAL SYSTEM Headlight Circuit Fan Installation .Tighten the fan mounting bolt to the specified toruqe (see Exploded View in the Cooling System chapter). Fan Inspection .Remove the following. Surge Tank Baffle Plate .Disconnect the 2-pin connector in the fan leads.
ELECTRICAL SYSTEM 15-29 Cooling Fan Circuit Fuel Pump The pump operates when the starter button is pushed on or the engine is running. .Refer to the Starter Motor section for the Fuel Pump Wiring Diagram. When fuel level in the float bowl is low, the fuel pump operates to supply fuel into the float bowl.
15-30 ELECTRICAL SYSTEM Fuel Pump Relay Internal Resistance .Connect the pump leads to the battery using auxiliary wires as shown. *If the pump operates, check the pump relay. *If the pump does not operate, the pump is defective. *If the pump operates and the pump relay is normal, close the outlet hose while operating the fuel pump.
ELECTRICAL SYSTEM 15-31 Meters, Gauges Removal .Remove the following. Upper Fairing (see Frame chapter) Headlight Unit Speedometer Cable Upper End Wiring Connectors .Remove the meter unit by taking off the mounting nuts. A. Pull the bulb. Meter, Gauge Assembly Note .
15-32 ELECTRICAL SYSTEM * If these readings are not correct. the trouble is with the gauge and/or wiring. A. Tachometer B. Pointer flicks. Water Temperature Gauge Operation Inspection A. Sensor Connector B. Water Temperature Gauge .Check the water temperature gauge circuit wiring (see Wiring Inspection).
ELECTRICAL SYSTEM 15-33 Tachometer Circuit 6. Ignition Coil {#1, #4) 7. Spark Plug 8. 30A Main Fuse in Starter Relay 9. Battery 1. Ignition Switch 2. 6-Pin Connector 3. Tachometer 4. 4- Pin Connector 5. IC Igniter Water Temperature Gauge Circuit 5. Water Temperature Sensor 6.
15-34 ELECTRICAL SYSTEM Water Temperature Sensor Inspection .Suspend the sensor in a container of coolant so that the temperature sensing projection and threaded portion are submerged. .Using an ohmmeter, measure the internal resistance of the sensor across the terminal and the body at the temperatures shown in the table.
ELECTRICAL SYSTEM 15-35 Junction Box Fuse Inspection .Remove the fuse (see Fuse Removal). .Inspect the fuse element. * If it is blown out replace the fuse.
15-36 ELECTRICAL SYSTEM Starter Circuit .Remove the junction box (see Fuse Removal). .Check conductivity of the following numbered terminal by connecting the hand tester (special tool) and one 12 V battery to the junction box as shown. *If the relay does not work as specified.
ELECTRICAL SYSTEM 15-37 Junction Box Internal Circuit Electrical Wiring Wiring Inspection .Visually inspect the wiring for signs of burning, fraying, etc. *If any wiring is poor, replace the damaged wiring. .Pull each connector apart and inspect it for corrosion, dirt, and damage.
APPENDIX 16-1 Table 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 .
16-2 APPEN DIX Additional Considerations for Racing When a plug of the correct heat range is belng used, the electrodes will stay hot enough to keep all the carbon burned off, but cool enough to keep from damaging the engine and the plug itself.
APPENDIX 16-3 Spark Plug Condition Carbon Fouling Oil Fouling Overheating Nonnal Operation Standard Spark Plug Threads Diameter: 10 mm Pitch: 1 .0 mm Reach: 19 mm Spark Plug Inspection .
16-4 APPENDIX Troubleshooting Guide Cylinder, piston worn Piston ring bad (worn, weak, broken, or sticking) Piston ring/groove clearance excessive Cylinder head gasket damaged Cylinder head warped Val.
APPENDIX 16-5 Engine oil viscosity too high Drive train trouble Brake dragging Lubrication inadequate: Engine oil level too low Engine oil poor quality or incorrect Gauge incorrect: Water temperature .
16-6 APPENDIX Rear wheel misaligned Pawl spring broken Shift mechanism arm broken Jumps out of gear: Shift fork worn Gear groove worn Gear dogs and/or dog holes worn Shift drum groove worn Neutral pos.
APPENDIX 16-7 General Lubrication Lubrication .Before lubricating each part, clean off any rusty spots with rust remover and wipe off any grease, oil, dirt, or grime.
16-8 APPENDIX Nut, Bolt, and Fastener Tightness Standard Torque Table This table relating tightening torque to thread diameter, lists the basic torque for bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value.
APPENDIX 16-9 Units of Length Unit Conversion Table mile ft in 0.6214 3.281 0.03937 ~ Prefixes for Units: Units of Torque: N-m x 0.1020 N-m x 0.7376 N-m x 8.851 kg-m ft-Ib in-Ib = 9.807 7.233 86.80 N-m ft-Ib in-Ib kg-m kg-m kg-m x x x = Units of Mass: kg x g x 2.
Un punto importante, dopo l’acquisto del dispositivo (o anche prima di acquisto) è quello di leggere il manuale. Dobbiamo farlo per diversi motivi semplici:
Se non hai ancora comprato il Kawasaki ZX400-H2 è un buon momento per familiarizzare con i dati di base del prodotto. Prime consultare le pagine iniziali del manuale d’uso, che si trova al di sopra. Dovresti trovare lì i dati tecnici più importanti del Kawasaki ZX400-H2 - in questo modo è possibile verificare se l’apparecchio soddisfa le tue esigenze. Esplorando le pagine segenti del manuali d’uso Kawasaki ZX400-H2 imparerai tutte le caratteristiche del prodotto e le informazioni sul suo funzionamento. Le informazioni sul Kawasaki ZX400-H2 ti aiuteranno sicuramente a prendere una decisione relativa all’acquisto.
In una situazione in cui hai già il Kawasaki ZX400-H2, ma non hai ancora letto il manuale d’uso, dovresti farlo per le ragioni sopra descritte. Saprai quindi se hai correttamente usato le funzioni disponibili, e se hai commesso errori che possono ridurre la durata di vita del Kawasaki ZX400-H2.
Tuttavia, uno dei ruoli più importanti per l’utente svolti dal manuale d’uso è quello di aiutare a risolvere i problemi con il Kawasaki ZX400-H2. Quasi sempre, ci troverai Troubleshooting, cioè i guasti più frequenti e malfunzionamenti del dispositivo Kawasaki ZX400-H2 insieme con le istruzioni su come risolverli. Anche se non si riesci a risolvere il problema, il manuale d’uso ti mostrerà il percorso di ulteriori procedimenti – il contatto con il centro servizio clienti o il servizio più vicino.
