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Kawasaki FJ400D - User Manual

Kawasaki FJ400D
129 pages
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FJ400D
4-stroke air-cooled gasoline engine
Service Manual

Table of Contents

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Summary

Quick Reference Guide

General Information

Provides general information about the engine.

Periodic Maintenance

Details regular maintenance procedures and schedules.

Fuel System

Covers fuel system components and adjustments.

Cooling System

Explains the engine's cooling system.

Engine Top End

Details the engine's top-end components and service.

Lubrication System

Covers lubrication system components and maintenance.

Camshaft;Crankshaft

Details camshaft and crankshaft systems.

Electrical System

Covers electrical system components and diagnostics.

Troubleshooting

Provides guidance for diagnosing engine issues.

LIST OF ABBREVIATIONS

EMISSION CONTROL INFORMATION

Crankcase Emission Control System

Explains the crankcase emission control system.

Exhaust Emission Control System

Explains the exhaust emission control system.

TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED

Warns against tampering with emission control systems.

Foreword

How to Use This Manual

Explains how to navigate and use the service manual.

General Information

Before Servicing

Details pre-service checks and precautions.

Model Identification

Shows how to identify the engine model.

General Specifications

Lists key specifications for the engine.

Periodic Maintenance

Periodic Maintenance Chart

Outlines the maintenance schedule and tasks.

Torque and Locking Agent

Lists torque specifications and locking agent requirements.

Specifications

Lists specifications for various engine systems.

Special Tools

Identifies special tools required for maintenance.

Periodic Maintenance Procedures

Details specific maintenance tasks and steps.

Fuel System

Exploded View

Illustrates fuel system components with part numbers.

Specifications

Lists specifications for the fuel system.

Governor Link Mechanism

Explains the governor linkage and its components.

Carburetor

Details carburetor function, maintenance, and specifications.

Cooling System

Exploded View

Illustrates cooling system components.

Cooling Fan

Details inspection and maintenance of the cooling fan.

Engine Top End

Exploded View

Illustrates engine top-end components.

Specifications

Lists specifications for cylinder head, valves, and piston.

Special Tools

Identifies special tools for engine top-end work.

Cylinder Head

Details cylinder head removal, installation, and inspection.

Valves

Covers valve inspection, adjustment, and repair.

Cylinder, Piston

Details piston and cylinder removal, installation, and inspection.

Lubrication System

Exploded View

Illustrates lubrication system components.

Engine Oil Flow Chart

Shows the flow of oil through the engine.

Specifications

Lists specifications for engine oil and oil pump.

Special Tools and Sealant

Lists special tools and sealants for lubrication system.

Engine Oil and Oil Filter

Covers oil level, changes, and filter replacement.

Pressurized Lubrication System

Explains the pressurized lubrication system and oil pressure.

Oil Pump, Relief Valve

Details oil pump and relief valve removal, installation, and inspection.

Oil Screen

Covers oil screen removal, installation, and cleaning.

Camshaft;Crankshaft

Exploded View

Illustrates camshaft and crankshaft components.

Specifications

Lists specifications for camshaft, crankshaft, and connecting rod.

Special Tool

Identifies a special tool for bearing installation.

Crankcase

Covers crankcase cover removal, installation, and inspection.

Breather

Explains the function and operation of the breather system.

Camshaft, Tappet

Details camshaft and tappet removal, installation, and inspection.

Crankshaft, Connecting Rod

Covers crankshaft and connecting rod removal, installation, and inspection.

Balancer Shaft

Details balancer shaft removal, installation, and wear inspection.

Electrical System

Exploded View

Illustrates electrical system components.

Specifications

Lists specifications for charging, ignition, and starter systems.

Special Tool

Identifies a special tool for electrical testing.

Wiring Diagram

Provides the electrical wiring diagram for the engine.

Precautions

Lists important precautions for servicing electrical systems.

Charging, Ignition System

Covers flywheel, stator, and ignition coil service.

Electric Starter System

Details starter motor and solenoid testing and disassembly.

Troubleshooting

Engine Troubleshooting Guide

Provides a guide for diagnosing common engine malfunctions.

Starter Motor Troubleshooting Guide

Guides troubleshooting for starter motor issues.

Summary

Quick Reference Guide

General Information

Provides general information about the engine.

Periodic Maintenance

Details regular maintenance procedures and schedules.

Fuel System

Covers fuel system components and adjustments.

Cooling System

Explains the engine's cooling system.

Engine Top End

Details the engine's top-end components and service.

Lubrication System

Covers lubrication system components and maintenance.

Camshaft;Crankshaft

Details camshaft and crankshaft systems.

Electrical System

Covers electrical system components and diagnostics.

Troubleshooting

Provides guidance for diagnosing engine issues.

LIST OF ABBREVIATIONS

EMISSION CONTROL INFORMATION

Crankcase Emission Control System

Explains the crankcase emission control system.

Exhaust Emission Control System

Explains the exhaust emission control system.

TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED

Warns against tampering with emission control systems.

Foreword

How to Use This Manual

Explains how to navigate and use the service manual.

General Information

Before Servicing

Details pre-service checks and precautions.

Model Identification

Shows how to identify the engine model.

General Specifications

Lists key specifications for the engine.

Periodic Maintenance

Periodic Maintenance Chart

Outlines the maintenance schedule and tasks.

Torque and Locking Agent

Lists torque specifications and locking agent requirements.

Specifications

Lists specifications for various engine systems.

Special Tools

Identifies special tools required for maintenance.

Periodic Maintenance Procedures

Details specific maintenance tasks and steps.

Fuel System

Exploded View

Illustrates fuel system components with part numbers.

Specifications

Lists specifications for the fuel system.

Governor Link Mechanism

Explains the governor linkage and its components.

Carburetor

Details carburetor function, maintenance, and specifications.

Cooling System

Exploded View

Illustrates cooling system components.

Cooling Fan

Details inspection and maintenance of the cooling fan.

Engine Top End

Exploded View

Illustrates engine top-end components.

Specifications

Lists specifications for cylinder head, valves, and piston.

Special Tools

Identifies special tools for engine top-end work.

Cylinder Head

Details cylinder head removal, installation, and inspection.

Valves

Covers valve inspection, adjustment, and repair.

Cylinder, Piston

Details piston and cylinder removal, installation, and inspection.

Lubrication System

Exploded View

Illustrates lubrication system components.

Engine Oil Flow Chart

Shows the flow of oil through the engine.

Specifications

Lists specifications for engine oil and oil pump.

Special Tools and Sealant

Lists special tools and sealants for lubrication system.

Engine Oil and Oil Filter

Covers oil level, changes, and filter replacement.

Pressurized Lubrication System

Explains the pressurized lubrication system and oil pressure.

Oil Pump, Relief Valve

Details oil pump and relief valve removal, installation, and inspection.

Oil Screen

Covers oil screen removal, installation, and cleaning.

Camshaft;Crankshaft

Exploded View

Illustrates camshaft and crankshaft components.

Specifications

Lists specifications for camshaft, crankshaft, and connecting rod.

Special Tool

Identifies a special tool for bearing installation.

Crankcase

Covers crankcase cover removal, installation, and inspection.

Breather

Explains the function and operation of the breather system.

Camshaft, Tappet

Details camshaft and tappet removal, installation, and inspection.

Crankshaft, Connecting Rod

Covers crankshaft and connecting rod removal, installation, and inspection.

Balancer Shaft

Details balancer shaft removal, installation, and wear inspection.

Electrical System

Exploded View

Illustrates electrical system components.

Specifications

Lists specifications for charging, ignition, and starter systems.

Special Tool

Identifies a special tool for electrical testing.

Wiring Diagram

Provides the electrical wiring diagram for the engine.

Precautions

Lists important precautions for servicing electrical systems.

Charging, Ignition System

Covers flywheel, stator, and ignition coil service.

Electric Starter System

Details starter motor and solenoid testing and disassembly.

Troubleshooting

Engine Troubleshooting Guide

Provides a guide for diagnosing common engine malfunctions.

Starter Motor Troubleshooting Guide

Guides troubleshooting for starter motor issues.

Kawasaki FJ400D Specifications

General IconGeneral
Fuel SystemCarburetor
Cooling SystemAir-cooled
Engine Type4-stroke, single cylinder
Starting SystemElectric starter
Lubrication SystemForced lubrication
Displacement401 cm³ (24.5 cu in)

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