Manual Kawasaki ZX400-H2

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  • Kawasaki ZX400-H2 - page 1

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  • Kawasaki ZX400-H2 - page 2

    Final Drive "" ...

  • Kawasaki ZX400-H2 - page 3

    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 Cable, Wire, and Hose Routing ...

  • Kawasaki ZX400-H2 - page 4

    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. Nevertheless. even a detailed account has limitations, a certain ...

  • Kawasaki ZX400-H2 - page 5

    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. Seals should be pressed into place using a suitable driver, which contacts evenly with the side ...

  • Kawasaki ZX400-H2 - page 6

    1-4 GENERAL INFORMATION Model Identification ZX400-H2 Left Side View: ZX400-H2 Right Side View: ...

  • Kawasaki ZX400-H2 - page 7

    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 16.0 L Front Rear Fuel tank capacity 1 3.5 m from 50 km/h 3.2 m Performance: Braking distan ...

  • Kawasaki ZX400-H2 - page 8

    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 3.000 ( 45/15) 7.317 @Top gear Type Reduction ratio Overall drive ratio Fr ...

  • Kawasaki ZX400-H2 - page 9

    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. Torque and locking Agent The following tables list the tighten ...

  • Kawasaki ZX400-H2 - page 10

    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 14.5 11.0 L L Oil Pressure Switch Terminal Oil Pressure Switch Oil Pump Cover Screws Oil Plug (Rig ...

  • Kawasaki ZX400-H2 - page 11

    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 3.2 23 13 8.8 1.3 0.90 113 in-Ib 78 in-Ib Side Stand Brack ...

  • Kawasaki ZX400-H2 - page 12

    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. ...

  • Kawasaki ZX400-H2 - page 13

    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 .-- ~ ~~ Run the horse under the cross pipe. 'A ( ~ ~ >~Iamp ~ ~ ~ /1 ...

  • Kawasaki ZX400-H2 - page 14

    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. To Oil Pressure Switch, Neutral Switch and Side Stand Switch 11. Alternator Lead 12. Batt ...

  • Kawasaki ZX400-H2 - page 15

    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.ToHorn 2. Ignition Switch Lead 3. To Ignition Coil 4. To Ra ...

  • Kawasaki ZX400-H2 - page 16

    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. Alternator Lead 2. To Oil Pressure Switch 3. To Neutral Switch 4. Side Stand Switch Lead 5. Battery ( -) Lead " Side Stand Switch (QJ:l ~ -- ...

  • Kawasaki ZX400-H2 - page 17

    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 ...2-9 ...2-9 ...2-9 .2-10 .2-10 .2-10 .2-10 .2-10 .2-11 .2-11 .2-11 Exploded View Specifications Special Tools , Throttle Grip and Cables Throttle Cable Adjustment Choke Cable Choke Cable Adjustment S ...

  • Kawasaki ZX400-H2 - page 18

    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 Main jet Standard Option Main air jet Needle jet Jet needle mark Pilot jet (slow jet) Pilot air jet Pilot screw Starter jet Service fuel level Float h ...

  • Kawasaki ZX400-H2 - page 21

    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. .Tighten the locknuts. .Check that the throttle linkage lever stops against t ...

  • Kawasaki ZX400-H2 - page 22

    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). O Determine the amount of choke cable play at the choke lever. Pull the choke lever until ...

  • Kawasaki ZX400-H2 - page 23

    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 .Remove the air cleaner housing. A. Air Cl ...

  • Kawasaki ZX400-H2 - page 24

    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. Then turn out the drain plug to feed fuel to the gauge. Idle Speed Adjustment .Start the eng ...

  • Kawasaki ZX400-H2 - page 25

    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. Fuel Tank (see Fuel Tank Removal) Surge Tank (see Surge Tank Removal) Air Cleaner Housin ...

  • Kawasaki ZX400-H2 - page 26

    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. ...

  • Kawasaki ZX400-H2 - page 27

    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. Mounting Bolt ...

  • Kawasaki ZX400-H2 - page 28

    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 .3-10 .3-10 .3-10 .3-10 Exploded View Specifications ,' Special Tool Sealant Coolant Flow Chart Coolant Coolant Level Inspection Coolant Draining Coolant Filling Pressure Testing Water Pump , R ...

  • Kawasaki ZX400-H2 - page 29

    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 (0.9 kg-m. 78 in-Ib) T5 : 18 N-m (1.8 kg-m.13 ft-Ib) l : Apply a non-permanent locking agent to the th ...

  • Kawasaki ZX400-H2 - page 30

    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 (0.95 -1 .25 kg/cm2, 14 -18 psi) Radiator: Cap relief pressure 80.0 -84.0°C (17 ...

  • Kawasaki ZX400-H2 - page 31

    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. ...

  • Kawasaki ZX400-H2 - page 32

    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. .Check the coolant level from between the fuel ta ...

  • Kawasaki ZX400-H2 - page 33

    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 (1.25 kg/cm2, 18 psi). A. Radiator B. Filler Neck ...

  • Kawasaki ZX400-H2 - page 34

    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). Removal .Remove the fairings. .Drain the coolant by removing the water pump drai ...

  • Kawasaki ZX400-H2 - page 35

    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. A. Rad ...

  • Kawasaki ZX400-H2 - page 36

    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. Radiator Cap Inspect ...

  • Kawasaki ZX400-H2 - page 37

    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 .Remove the thermostat housir,g on the cylinder. .Remove the thermostat from the hou ...

  • Kawasaki ZX400-H2 - page 38

    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 4-8 Installation 4-8 Camshaft Chain Tensioner 4-9 Removal 4-9 Installation 4-9 Camshaft 4-10 Camshaft Removal 4-10 Camshaft Installation 4-11 Camshaft, ...

  • Kawasaki ZX400-H2 - page 39

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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: 8.8 N-m (0.9 kg-m. 78 in-Ib) T2: 9.8 N-m (1.0 kg-m. 7.0 ft-Ib) T3: 12 ...

  • Kawasaki ZX400-H2 - page 41

    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 0.21 mm 23.92 mm 23.87 mm 24.08 mm 0.1 mm TIR 1 28.9 mm Inlet Exhaust Camshaft, camshaft cap clearance A B Camshaft journal diameter: A B Camshaft bearing inside diameter Camshaft runout Camshaft chain ...

  • Kawasaki ZX400-H2 - page 42

    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 ~ 57.000 -57.01 2 mm 56.942 -56.957 mm 0.043 -0.070 mm + 0.5 m ...

  • Kawasaki ZX400-H2 - page 43

    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 Compressor Assembly: 57001-241 Valve Seat Cutter Holder, <!>4: 57001-1275 Valve Spring Compressor Adapter, <1>21: 57001-1272 Valve Seat Cut ...

  • Kawasaki ZX400-H2 - page 44

    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 ...

  • Kawasaki ZX400-H2 - page 45

    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 .Remove the cylinder head cover bolts and take off the cover. A. Bolts B. Cylinder Head ...

  • Kawasaki ZX400-H2 - page 46

    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. c. Lock Bolt A. Camshaft Chai ...

  • Kawasaki ZX400-H2 - page 47

    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) .Remove the following. Carburetor (see Fuel ...

  • Kawasaki ZX400-H2 - page 48

    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. Camshaft Installation .Installation is the reverse of removal. Note the follow- in ...

  • Kawasaki ZX400-H2 - page 49

    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. #4 Journals Standard: 0.028 -0.071 mm Service limit: 0.16 mm #2. #3 Journals Standard: 0.0 ...

  • Kawasaki ZX400-H2 - page 50

    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. and take off the rocker arms. - 1. Springs (conical) 2. Springs .Tighten the followi ...

  • Kawasaki ZX400-H2 - page 51

    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) .Remove the cylinder head bolts and take off the cylinde ...

  • Kawasaki ZX400-H2 - page 52

    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. OWhen positioning #4 piston TDC at the end o ...

  • Kawasaki ZX400-H2 - page 53

    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. NOTE 0 Mark and record shim locations so they can be reinstalled in their ...

  • Kawasaki ZX400-H2 - page 54

    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 ~ 21.7 mm 18.5 ~ 18.7 mm Valve Seat Outside Diameter Standard: Inlet : Exhaust : Valve Seat Repair {Val ...

  • Kawasaki ZX400-H2 - page 55

    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. NOTE 0 Prior to grinding, apply engine oil to the cutter and during the oper ...

  • Kawasaki ZX400-H2 - page 56

    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. .Inse ...

  • Kawasaki ZX400-H2 - page 57

    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. .Using the piston base (special tools), install the cylinder bloc ...

  • Kawasaki ZX400-H2 - page 58

    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. @-- t} @@ 4. Oil Ring Expander 5. Arrow 1.TopRing 2. Second Ring 3. Oil Ring Steel Rail ...

  • Kawasaki ZX400-H2 - page 59

    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. Set it close to the bottom of the cylinder, where cylinder wear is low. ...

  • Kawasaki ZX400-H2 - page 60

    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. A. Carburetor Holders B. Inlet Pipes A. Nuts B. Holder .Take off the ...

  • Kawasaki ZX400-H2 - page 61

    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... Clutch Cover Removal Clutch Cover Installation Note , ...

  • Kawasaki ZX400-H2 - page 62

    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. , ...

  • Kawasaki ZX400-H2 - page 63

    CLUTCH 5-3 Specifications Special Tools Sealant ...

  • Kawasaki ZX400-H2 - page 64

    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 .Pull the clutch lever just enough to take up the free play. .Measure the gap between the leve ...

  • Kawasaki ZX400-H2 - page 65

    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). .Remove the lower fairing (see Lower Fairing Removal in Frame chapter). .Remove ...

  • Kawasaki ZX400-H2 - page 66

    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. Pay .Tighten the clutch cover bolts to the specified torque (see Exploded ...

  • Kawasaki ZX400-H2 - page 67

    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). . 1 .Spacer 2. Needle Bearing 3. Collar 4. Clutch Housing 5. Washe ...

  • Kawasaki ZX400-H2 - page 68

    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. Friction or Steel Plate Warp Inspection .Place eac ...

  • Kawasaki ZX400-H2 - page 69

    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 Oil Flow Chart Specifications Special Tools Sealant Engine Oil and Oil Filter Oil Level Inspection Engine Oil Change Oil Filter Change Oil Pan Removal ...

  • Kawasaki ZX400-H2 - page 70

    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 (1.75 kg-m. 12.5 ft-Ib) T7: 20 N-m (2.0 kg-m. 14.5 ft-Ib) T8: 29 N-m (3.0 kg-m. 22 ft-I ...

  • Kawasaki ZX400-H2 - page 71

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  • Kawasaki ZX400-H2 - page 72

    6-4 ENGINE LUBRICATION SYSTEM Engine Oil Flow Chart @- ...

  • Kawasaki ZX400-H2 - page 73

    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. Output Shaft 15. Drive Shaft 16. Crankshaft 17. Water Pump 18. Oil Pan 19. Oil ...

  • Kawasaki ZX400-H2 - page 74

    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. M18 x 1.5: 57001-1278 ...

  • Kawasaki ZX400-H2 - page 75

    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. .Check that the engine oil level is between the upper and lower levels in ...

  • Kawasaki ZX400-H2 - page 76

    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. 'Removal .Set the motorcycle on its side stand. .Remove the following. Low ...

  • Kawasaki ZX400-H2 - page 77

    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. Relief Valve B. Oil Pump Filter c. Unround Portion ...

  • Kawasaki ZX400-H2 - page 78

    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 .Drain the engine oil. .Remove the lower fairing (see Frame chapter). .Remove the Allen bolts from ...

  • Kawasaki ZX400-H2 - page 79

    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. A. Oil Pressure Gauge: 57001 -1 64 B. Adapter: 57001 -1278 Oil Pressure Standard ...

  • Kawasaki ZX400-H2 - page 80

    ENGINE REMOVAL / INSTALLATION 7-1 T able of Contents Exploded View 7 - Special Tool : Engine Removal/Installation ,.., , Removal , , Installation 7 -4 ...

  • Kawasaki ZX400-H2 - page 81

    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. ...

  • Kawasaki ZX400-H2 - page 82

    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 System chapter) Coolant (Drain, see Cooling System chapter) Fuel Tank (see Fuel System chapter) Air Cleaner Housing (see Fuel System chapter) Carburetor ...

  • Kawasaki ZX400-H2 - page 83

    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. A. Bracket B. Bracket Bolts and Nuts C. Engine Moun ...

  • Kawasaki ZX400-H2 - page 84

    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 ..8-14 ..8-14 ..8-14 ..8-14 ..8-14 ..8-14 ..8-15 ..8-15 ..8-15 ..8-17 ..8-17 ..8-17 ..8-17 Exploded View Specifications , , ; Special Tools , , Sealant Crankcase Crankcase Splitting , Crankcase Assemb ...

  • Kawasaki ZX400-H2 - page 85

    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: 9.8 N-m (1.0 kg-m. 7.0 ft-Ib) T3: 12 N-m (1.2 kg-m. 8.5 ft-Ib) T4: 15 N-m (1.5 kg-m. 11.0 ft-Ib) T5 ...

  • Kawasaki ZX400-H2 - page 86

    ...

  • Kawasaki ZX400-H2 - page 87

    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 .480 -1 .4 ...

  • Kawasaki ZX400-H2 - page 88

    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 6.3mm Transmission: Shift fork ear thickness Gear shift fork groove width Shift fork guide pin diameter Shift drum groove width ...

  • Kawasaki ZX400-H2 - page 89

    8-6 CRANKSHAFT / TRANSMISSION Special Tools Sealant Socket Wrench, Hex 8: 57001 -1268 Outside Circlip Pliers: 57001-144 ~ Beari~g Driver Set: 57001 -1129 ...

  • Kawasaki ZX400-H2 - page 90

    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. .Remove the following. Cylinder Head (if the cr ...

  • Kawasaki ZX400-H2 - page 91

    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. .Tighten the crankcase mounting bolts following the tightening seque ...

  • Kawasaki ZX400-H2 - page 92

    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. Crankshaft Installation .Apply high temperature grease to the output shaft oil seal lips and ...

  • Kawasaki ZX400-H2 - page 93

    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. 1 .Big End Cap 2. Connecting Rod 3. Weight Mark, Alphabet .Apply engine oil to ...

  • Kawasaki ZX400-H2 - page 94

    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 (0.10 mm), replace the bearing inserts with inserts painted blue. Check insert/c ...

  • Kawasaki ZX400-H2 - page 95

    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. replace the crankshaft with a new one. * If the measured journal diameters are not less t ...

  • Kawasaki ZX400-H2 - page 96

    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 .Insert a thickness gauge between the crankcase and the crankweb at the No.2 journa ...

  • Kawasaki ZX400-H2 - page 97

    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. A. Shift Mechanism Arm B. Shift Drum Set Lever c. Set Lever Spring Shift Pedal ...

  • Kawasaki ZX400-H2 - page 98

    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. 3. Steel Balls 1. Gear 2. Shaft Transmission D ...

  • Kawasaki ZX400-H2 - page 99

    8-16 CRANKSHAFT / TRANSMISSION ...

  • Kawasaki ZX400-H2 - page 100

    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). .While holding the shift drum with a vise, remove the shift drum cam bolt. Shi ...

  • Kawasaki ZX400-H2 - page 101

    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 ,. Special Tools Wheels ( Rims) Front Wheel Removal Front Wheel Installation Rear Wheel Removal , Rear Wheel Installation Wheel Inspection Balance Weight Installation Balance Weight ...

  • Kawasaki ZX400-H2 - page 102

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

  • Kawasaki ZX400-H2 - page 103

    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 (2.50 kg/cm2, 36 psi) 4.0mm 6.0mm I 1 mm 2mm (Up to 130 km/h) 3mm (Over 130 ...

  • Kawasaki ZX400-H2 - page 104

    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 ...

  • Kawasaki ZX400-H2 - page 105

    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. A. Caliper Mounting Bolts B. Speedometer Cable Lower End Right Side ...

  • Kawasaki ZX400-H2 - page 106

    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). Axle Nut Axle Clamp Bolts Caliper Mounting Bolts .Check the front ...

  • Kawasaki ZX400-H2 - page 107

    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. Replace the loose balance weight. Do not reuse used balance weight. Balance Weight ...

  • Kawasaki ZX400-H2 - page 108

    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. Removing Balance Weight (without tire on rim) NOTE 0 Measure the tire pressure when th ...

  • Kawasaki ZX400-H2 - page 109

    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. Stem Seal 4. Valve Stem 5. Valve Seat 6. Valve Opened .Install a new valve in the rim. O Remove ...

  • Kawasaki ZX400-H2 - page 110

    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). .Install the brake disc(s) so tha ...

  • Kawasaki ZX400-H2 - page 111

    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 .Use the bearing remover (special tool) to remove the hub bearings I --1 .Install th ...

  • Kawasaki ZX400-H2 - page 112

    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... Lubrication Drive Chain Removal Drive Chain Installation Sprocket Cou ...

  • Kawasaki ZX400-H2 - page 113

    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. ...

  • Kawasaki ZX400-H2 - page 114

    FINAL DRIVE 10-3 Specifications Special Tools Jack: 57001 -1238 ~ Inside Circlip Pliers: 57001-143 ~ ~ ~ I I ...

  • Kawasaki ZX400-H2 - page 115

    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.Axle D. Torque Link Nut + OTurn the chain adjusters forward or rearward until the drive c ...

  • Kawasaki ZX400-H2 - page 116

    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. Lower Fairings (see Frame chapter) Chain Cover Engine Sprocket Cover (see this ...

  • Kawasaki ZX400-H2 - page 117

    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. Bolt (locking agent) Drive Chain Installation .Installation is the reverse of removal. Note t ...

  • Kawasaki ZX400-H2 - page 118

    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. .Remove the rear sprocket nuts. .Remove the rear sprocket. Direction of rotation R ...

  • Kawasaki ZX400-H2 - page 119

    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 .11-14 .11-14 .11-14 .11-14 .11-14 Exploded View , , Specifications Special Tools Brake Fluid Fl ...

  • Kawasaki ZX400-H2 - page 120

    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 (2.1 kg-m.15.0 ft-Ib) T8: 23 N-m (2.3 kg-m. 16.5 ft-Ib) T9: 25 N-m (2.5 kg-m. 18.0 ft-Ib) T10: 27 ...

  • Kawasaki ZX400-H2 - page 121

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

  • Kawasaki ZX400-H2 - page 122

    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 Castrol Girling- Universal Castrol GT ( LMA) Castrol Disc Brake Fluid Non -adjustable Brake Lever Free Play: Brake Pedal: Brake pedal free play Brake p ...

  • Kawasaki ZX400-H2 - page 123

    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.O.T.3. Recommended Disc Brake Fluid Fluid Level Inspection In accordance with the Periodic Maintenance Chart, inspect the brake fluid ...

  • Kawasaki ZX400-H2 - page 124

    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. Air, however, is easily compressed. When air enters the brake line ...

  • Kawasaki ZX400-H2 - page 125

    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. 3. Release the brake. A. Footpeg B. Brake Pedal c. Pedal Position B. Bleed Valve A. Caliper .When ...

  • Kawasaki ZX400-H2 - page 126

    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 .Remove the caliper. B. 10 mm A. Brake Pedal *If it ...

  • Kawasaki ZX400-H2 - page 127

    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. Leave one of th ...

  • Kawasaki ZX400-H2 - page 128

    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. O For the rear caliper, install the dust seal around the piston an ...

  • Kawasaki ZX400-H2 - page 129

    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. Rear Brake Pad Removal .Remove the following. Rear Caliper (see this chapter) Plastic ...

  • Kawasaki ZX400-H2 - page 130

    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. Pad Lining Thickness (fro ...

  • Kawasaki ZX400-H2 - page 131

    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). Front Master Cylinder Installation .The master c ...

  • Kawasaki ZX400-H2 - page 132

    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. .Take care not to scratch the piston ...

  • Kawasaki ZX400-H2 - page 133

    BRAKES 11-15 Disc Runout Standard: Service Limit: Under 0.2 mm 0.3mm ...

  • Kawasaki ZX400-H2 - page 134

    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 ... Spring Prelo ...

  • Kawasaki ZX400-H2 - page 135

    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 (1.5 kg-m, 11.0 ft-Ib) T2: 20 N-m (2.0 kg-m, 14.5 ft-Ib) T3: 23 N-m (2.3 kg-m, 16. ...

  • Kawasaki ZX400-H2 - page 136

    ...

  • Kawasaki ZX400-H2 - page 137

    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 .6 mm Fork oil: Viscosity Amount (perside): when changing ...

  • Kawasaki ZX400-H2 - page 138

    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 /' "' , ,. " N ...

  • Kawasaki ZX400-H2 - page 139

    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. A. Rebound Damping Adjuster OThe standard adjus ...

  • Kawasaki ZX400-H2 - page 140

    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. Front Fork (see Front Fork Removal) Top Bolt Top Spring Main Spring .Pour out the fork oil wit ...

  • Kawasaki ZX400-H2 - page 141

    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). Fork Clamp Bolts (upper and lower) Front Fork ...

  • Kawasaki ZX400-H2 - page 142

    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. e Hold the axle holder in a vise. ...

  • Kawasaki ZX400-H2 - page 143

    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. Guide Bush O-ring of the Top Bolt .Remove the guide bush from the ...

  • Kawasaki ZX400-H2 - page 144

    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. The numbers on the adjuster show the setting position. 1 .Spring Length 2. Locknut 3. Adjust ...

  • Kawasaki ZX400-H2 - page 145

    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. drill a hole at a point shown to release the nitrogen gas completely. W ...

  • Kawasaki ZX400-H2 - page 146

    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. Swing Arm Shaft .Remove the swing arm. Ins ...

  • Kawasaki ZX400-H2 - page 147

    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. Refer to Rear Shock Removal in this chapter. .Remove the tie-rods. ...

  • Kawasaki ZX400-H2 - page 148

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

  • Kawasaki ZX400-H2 - page 149

    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. Steering Stem Warp ...

  • Kawasaki ZX400-H2 - page 150

    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 ~ . ~:: : ! , ~ 1 @~ A~ ...

  • Kawasaki ZX400-H2 - page 151

    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 ~ ~ ...

  • Kawasaki ZX400-H2 - page 152

    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) . OWith the front wheel pointing s ...

  • Kawasaki ZX400-H2 - page 153

    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 .Push up on the stem base, and remove the steering stem locknut using the stem nut wr ...

  • Kawasaki ZX400-H2 - page 154

    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. Pawl Washer 6. Washer .The following four steps should be performed after steering bea ...

  • Kawasaki ZX400-H2 - page 155

    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. which are press-fitted into the frame head pipe. clean of grease and di ...

  • Kawasaki ZX400-H2 - page 156

    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. Lower Fairing Removal ...

  • Kawasaki ZX400-H2 - page 157

    14-2 FRAME Exploded View ~ l Apply a non-permanent locking agent to the threads. ...

  • Kawasaki ZX400-H2 - page 158

    ...

  • Kawasaki ZX400-H2 - page 159

    ...

  • Kawasaki ZX400-H2 - page 160

    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. A. Mounting Bolt Front ...

  • Kawasaki ZX400-H2 - page 161

    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. Rear ...

  • Kawasaki ZX400-H2 - page 162

    FRAME 14-7 NOTE 0 Remove the lower fairings as assembly. ...

  • Kawasaki ZX400-H2 - page 163

    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 ...15-5 ...15-8 ...15-9 ...15-9 .1 5-1 O .15-10 .15-10 .15-10 .15-10 .15-11 .15-11 .15-11 .15-1 ...

  • Kawasaki ZX400-H2 - page 164

    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. Learn and observe all the rules below. O Do not reverse the ...

  • Kawasaki ZX400-H2 - page 165

    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.. -- 0 ~~~~ - Ii ~~ I -> -! ~ :~ []l ..~ ~i 0- rr ;: -;'.'.-.'..- ...

  • Kawasaki ZX400-H2 - page 166

    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. Water Temperature Sensor 14. Radiator Fan 15. Rear Brake Light Switch 16. Pickup Coil 17. Indic ...

  • Kawasaki ZX400-H2 - page 167

    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 (8.0 kg-m, 58 ft-Ib) < ~ ~ ~@<D ~ ~ .-':'" ~ @ J '@ ~ @CD I @ ~ ~ cC1 @ ~ ...

  • Kawasaki ZX400-H2 - page 168

    ...

  • Kawasaki ZX400-H2 - page 169

    ...

  • Kawasaki ZX400-H2 - page 170

    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) 0.2 -0.9 Q 355 -535 O Ignition System: Pickup coil resistance Ignition coil: 3 needle arci ...

  • Kawasaki ZX400-H2 - page 171

    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 Jack: 57001-1238 ...

  • Kawasaki ZX400-H2 - page 172

    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. *If the level of electrolyte ...

  • Kawasaki ZX400-H2 - page 173

    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. .Check the electrolyte level after charging. Alternator Cover Installat ...

  • Kawasaki ZX400-H2 - page 174

    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. .Holding the rotor puller, turn the rotor puller until the alternator rotor is ...

  • Kawasaki ZX400-H2 - page 175

    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. 4. Chamfer Stator Installation Notes .Fit the stator coil lead grommet first, and th ...

  • Kawasaki ZX400-H2 - page 176

    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). .Connect an ohmmeter to the regulator/rectifier as ...

  • Kawasaki ZX400-H2 - page 177

    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. Y3 Lead Terminal 1. W Lead Terminal 2. BR Lead Terminal 3. BK/Y Lead Terminal NOTE 0 The ...

  • Kawasaki ZX400-H2 - page 178

    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. If the above checks show the regulator/rectifier is not damaged, but ther ...

  • Kawasaki ZX400-H2 - page 179

    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. * Any meter reading less than inf ...

  • Kawasaki ZX400-H2 - page 180

    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. Timing Rotor 7. Ignition Coil (#1, #4 Cylinder) 8. Ignition Coil (#2, #3 Cylinder) 9. S ...

  • Kawasaki ZX400-H2 - page 181

    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. Plug Gap 4. Side Electrode 1. Insulator 2. Center Electrode IC Igniter Ins ...

  • Kawasaki ZX400-H2 - page 182

    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. .Pull the starter motor upwards with ...

  • Kawasaki ZX400-H2 - page 183

    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. A. Bolts B. End Covers .Be careful not to lose the brush springs. .Re ...

  • Kawasaki ZX400-H2 - page 184

    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. but the starter motor still does not turn over or only turns ...

  • Kawasaki ZX400-H2 - page 185

    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. Replace ...

  • Kawasaki ZX400-H2 - page 186

    ...

  • Kawasaki ZX400-H2 - page 187

    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. Headlight Beam Horizontal Adjustment .Turn the adjusting screw on ...

  • Kawasaki ZX400-H2 - page 188

    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. Headlight Unit Removal/lnsta!lation Note .Install the headlight unit so that the "T ...

  • Kawasaki ZX400-H2 - page 189

    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 .Using an auxiliary wire, connect the radiator fan switch leads. *If the fan rotate ...

  • Kawasaki ZX400-H2 - page 190

    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. A. Fan Connector .Using two auxiliary wires, supply battery power to the ...

  • Kawasaki ZX400-H2 - page 191

    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. When the fuel reaches a certain level, the f ...

  • Kawasaki ZX400-H2 - page 192

    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. .When the pump ...

  • Kawasaki ZX400-H2 - page 193

    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 .Install each lead on the original position shown. A. Meter Mounting Nuts A. W/Y Lea ...

  • Kawasaki ZX400-H2 - page 194

    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). .If all wiring and components other than the ...

  • Kawasaki ZX400-H2 - page 195

    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. Starter Relay 7. 30A Main Fuse 8. Battery 1. Ignition Switch 2. 6-Pin Con ...

  • Kawasaki ZX400-H2 - page 196

    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. Fan Switch Resistance 0 Ri ...

  • Kawasaki ZX400-H2 - page 197

    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. Before replacing a blown fuse, always check the amperage in the affected circuit. If the amperage is equal to or greater than the fuse rating, check the wiring and related components for a short ...

  • Kawasaki ZX400-H2 - page 198

    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. replace the junction box. Relay Circuit Inspection (with the battery dis ...

  • Kawasaki ZX400-H2 - page 199

    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. *If the connector is corroded or dirty, clean it carefully. If it is ...

  • Kawasaki ZX400-H2 - page 200

    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 ..16-9 ..16-9 Additional Considerations for Racing Carburetor: Spark Plug: Spark Plug Inspection , Troubleshooting Guide Clutch Operation Faulty: , General Lubrication Lubrication Nut, Bolt and F ...

  • Kawasaki ZX400-H2 - page 201

    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. This temperature is about 400 -800°C (750 -1 ,450°F} and can be judged by noting the condition and col ...

  • Kawasaki ZX400-H2 - page 202

    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 .Remove the spark plug and inspect the ceramic insulator. *Whether or not the right temperature plug is being used can be ascertained by noting the condition of the ...

  • Kawasaki ZX400-H2 - page 203

    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 Valve spring broken or weak Valve not seating properly (valve bent, worn, or carbon accumulation on the seating surface) NOTE 0 This is not an exhaustive ...

  • Kawasaki ZX400-H2 - page 204

    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 gauge broken Water temperature sensor broken Coolant incorrect: Coolant level too low Coolant deteriorated Cooling system component incorrect: Radiato ...

  • Kawasaki ZX400-H2 - page 205

    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 positioning pin spring weak or broken Shift fork pin worn Drive shaft, output shaft, and/or gear splines worn Overshifts: Neutral positioning lever sprin ...

  • Kawasaki ZX400-H2 - page 206

    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. .Lubricate the points listed below with indicated lubricant. air NOTE 0 Whenever the vehicle has been operated under wet or rainy conditions, or especially after using a high-pressure ...

  • Kawasaki ZX400-H2 - page 207

    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. Refer to each chapter for reference to these features. All of the values are for use with ...

  • Kawasaki ZX400-H2 - page 208

    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 2.205 0.03527 Ib oz ~ Units of Volume: L x 0.2642 L x 0.2200 L x 1.057 L x 0.8799 L x 2.1 ...

Manufacturer Kawasaki Category Utility Trailer

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