Kawasaki KZ400 Service Manual (English)

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Kawasaki

Motorcycle

Service

Manual

Kawasaki Heavy Industries, Ltd. 1979, 1980, 1981

Revised

Feb. 17, 1981

Quick Reference Guide4
Model Ldentification5
KZ500-B1 Left Side View5
KZ500-B1 Right Side View5
Table of Contents6
Specifications6
- Engine Performance Curves9
- Periodic Maintenance Chart11
- Adjustment-Engine12
- Spark Plugs13
- Ignition Timing13
- Spark Plug Gap13
- Timing Advancer13
- Timing Test (Static)14
- Point Gap Adjustment (Using a Dwell Angle Tester)14
- Point Gap Adjustment (Using a Thickness Gauge)14
- Timing Test (Dynamic)15
- Dynamic Ignition Timing Test15
- Valve Clearance16
- Inlet Valve Clearance Adjustment Chart17
- Exhaust Valve Clearance Adjustment Chart18
- Throttle Cables19
- Carburetors20
- Initial Synchronization-Mechanical20
- Throttle Valve Clearance21
- Throttle Valve Position at Fully Throttle21
- Idling Adjustment22
- Fine Synchronization-Vacuum22
- Clutch23
- To Synchronize the Carburetors23
- Engine Oil25
- Fuel System25
- Oil and Oil Filter Change25
- Oil Level Inspection25
- Adjustment-Chassis27
- Rear Shock Absorbers28
- Drive Chain28
- Drive Chain Slack28
- Front Brake29
- Rear Brake29
- Brake Pedal Position29
- Rear Brake Pedal Play29
- Brake Light Switch30
- Wheel Balance31
- Headlight32
- Balance Weight Installation32
- Horizontal Adjustment (Not on UK Model)32
- Vertical Adjustment32
- General Lubrication33
- Throttle Grip33
- Brake Lever33
- Clutch Lever33
- Clutch and Throttle Cables34
- Left Footpeg, Side Stand34
- Right Footpeg, Brake Pedal, Brake Push Rod Joint34
- Center Stand34
- Others35
- Carburetor Choke Link Mechanism35
- Disassembly-Introduction36
- Introduction to Disassembly37
- Torque and Locking Agent38
- Coarse Threads42
- Fine Threads42
- Disassembly-Engine Installed43
- Flow Chart44
- Fuel Tank45
- Fuel Tap46
- Air Cleaner Element47
- Separation of Carburetors49
- Carburetors50
- Choke Mechanism Adjustment51
- Throttle Valve, Jet Needle Removal52
- Fast Ldle Mechanism52
- Fast Ldle Mechanism Adjustment52
- Choke Valve Removal53
- Mufflers54
- Ignition Coils55
- Camshafts55
- Camshaft Cap Tightening Order57
- Cam Chain Timing57
- Camshaft Sprockets59
- Cylinder Head59
- Camshaft Sprocket Installation59
- Valves, Valve Guides60
- Cylinder Head Nut Tightening Order60
- Valve and Valve Guide61
- Cylinder Block62
- Cylinder Block Pry Point62
- Piston Ring Openings (Front Side View)63
- Camshaft Chain Guides (Upper, Front, Rear)64
- Pistons, Piston Rings65
- Front Camshaft Chain Guide Installation65
- Breather Cover66
- Top Ring, Second Ring66
- Oil Ring Expander Installation66
- Engine Sprocket Cover67
- Clutch Release68
- Engine Sprocket69
- External Shift Mechanism69
- Neutral Switch71
- Starter Motor71
- Alternator Stator73
- Alternator Rotor74
- Contact Breakers74
- Capacitors75
- Oil Pressure Switch79
- Oil Filter, Bypass Valve79
- Oil Pressure Relief Valve80
- Engine Oil Pump81
- Secondary Shaft Starter Motor Clutch82
- Secondary Shaft, Starter Motor Clutch84
- Starter Motor Idle Gear85
- Ball Bearing Installation85
- Disassembly-Engine Removed87
- Engine Removal90
- Engine Mounting Bolt Length and Torque93
- Crankcase Split94
- Transmission102
- Shift Drum104
- Drive Shaft104
- Circlip and Splined Washer Installation106
- Drive Shaft Gears106
- Crankshaft (Including Connecting Rods), Camshaft Chain, and Primary Chain107
- Output Shaft107
- Output Shaft Gears107
- Connecting Rods108
- Disassembly- Chassis110
- Front Wheel112
- Speedometer Gear Housing Disassembly113
- Bearing, Brake Disc Removal114
- Wheel Bearing Removal114
- Bearing, Brake Disc Installation114
- Front Disc Brake115
- Pad Installation115
- Caliper Removal (each Caliper)116
- Caliper Installation Notes116
- Caliper Disassembly117
- Caliper Assembly118
- Master Cylinder Installation Notes118
- Master Cylinder Removal118
- Front Master Cylinder119
- Master Cylinder Assembly Notes120
- Brake Hose Replacement120
- Master Cylinder Disassembl120
- Rear Wheel120
- Wheel Installation121
- Wheel Coupling, Rear Sprocket Installation Notes123
- Rear Disc Brake124
- Bearing, Brake Disc Lnstallation Notes124
- Pad Removal124
- Caliper Removal125
- Rear Caliper126
- Caliper Fluid Seal, Dust Seal127
- Master Cylinder Disassembly128
- Master Cylinder Assembly128
- Rear Master Cylinder Installation128
- Rear Master Cylinder129
- Tires, Tubes130
- Clutch Cable131
- Throttle Cables131
- Speedometer Cable133
- Tachometer Cable133
- Headlight Unit134
- Indicator Lights (Left and Right Turn, High Beam, Neutral(134
- Headlight, Front Turn Signal134
- Turn Signal Lights135
- Bulb Replacement135
- Turn Signal Assemblys135
- Rear Turn Signal136
- Speedometer, Tachometer, Meter Lights, Indicator Lights (Oil, Stop Lamp)137
- Tail/Brake Light137
- Rear Brake Light Switch138
- Front Brake Light Switch138
- Ignition Switch138
- Starter Lockout Switch139
- Handlebar139
- Steering Stem141
- Steering Stem Bearings143
- Front Fork144
- Rear Shock Absorbers147
- Swing Arm148
- Maintenance- Engine150
- Air Cleaner151
- Cleaning and Replacement151
- Fuel Tank, Fuel Tap152
- Inspection and Cleaning152
- Carburetor Constructions153
- Carburetor153
- Starter System154
- Fast Idle Mechanism155
- Pilot System155
- Pilot System Fuel and Air Supply156
- Flow Characteristi156
- Main System156
- Cutaway157
- Main System Fuel and Air Supply157
- Float System158
- Service Fuel Level Measurement and Adjustment158
- Service Fuel Level Measurement158
- Camshaft159
- Valve Needle159
- Camshaft Runout160
- Cam Height Measurement160
- Journal, Bearing Wear160
- Camshaft Chain, Guide, Tensioner161
- Camshaft Chain Wear161
- Chain Length Measurement161
- Camshaft Chain Tensioner (Cross-Wedge Type)161
- Cylinder Head, Valve162
- Chain Guide Wear162
- Chain Guide Rubber Wear162
- Cleaning and Inspection162
- Measuring Plastic Plate163
- Valve, Valve Guide, Valve Seat163
- Valve Inspection163
- Valve Guide Inspection164
- Valve Stem Bend164
- Valve Shape164
- Valve Seat Repair165
- Valve Seating Width165
- Cutting Angle of Valve Seat165
- Valve/Valve Seat Contact Area165
- Inlet Valve Stem Installed Height166
- Exhaust Valve Stem Installed Height166
- Valve Stem Height Inspection167
- Valve Installed Height167
- Valve Spring167
- Spring Tension167
- Cylinder Block, Pistonvalve Spring Squareness168
- Oil Seal168
- Compression Measurement168
- Cylinder Inside Diameter Measurement169
- Cylinder, Piston Wear169
- Piston/Cylinder Clearance170
- Piston Cleaning170
- Boring, Honing170
- Piston Ring, Piston Ring Groove Wear170
- Piston, Piston Pin, Connecting Rod Wear171
- Piston Ring End Gap (Top, Second)171
- Crankshaft, Connecting Rod172
- Connecting Rod Bend, Twist172
- Connecting Rod Bend Measurement172
- Connecting Rod Bearing Insert/Journal Wear172
- Crankshaft Runout173
- Crankshaft Bearing Insert/Journal Wear174
- Crankshaft Side Clearance175
- Oil Passage Cleaning175
- Secondary Shaft175
- Primary Chain176
- Clutch Trouble177
- Friction Plate Wear, Damage177
- Clutch Housing Gear Damage178
- Clutch Plate Warp178
- Friction Plate / Clutch Housing Clearane178
- Clutch Housing Gear/Secondary Shaft Gear Backlash179
- Clutch Housing/Drive Shaft Sleeve Wear179
- Shift Mechanism179
- Clutch Hub Damage179
- Transmission180
- Transmission Trouble182
- Shift Arm and Overshift Limiter Operation182
- Overshift Limiter182
- Neutral Locator182
- Gear Backlash183
- Shift Fork Bending183
- Shift Fork/Gear Groove Wear183
- Shift Fork Guide Pin/Shift Drum Groove Wear184
- Shaftheedle Bearing Outer Race Wear184
- Gear Dog, Gear Dog Hole, Gear Dog Recess Damage184
- Gear/Shaft Clearance184
- Engine Lubrication185
- Oil Pressure Switch, Relief Valve185
- Oil Pressure Measurement185
- Engine Oil Flow Chart186
- Engine Lubrication System186
- Oil Pressure Switch Inspection187
- Relief Valve Inspection187
- Outer Rotor/Inner Rotor Clearance187
- Oil Filter188
- Outer Iotor/Pump Body Clearance188
- Rotor Side Clearance188
- Oil Filter Replacement188
- Ball Bearing, Needle Bearing189
- Muffler189
- Oil Breather189
- Oil Seal Damage189
- Maintenance-Chassis190
- Rim Runout Measurement191
- Rim191
- Tire191
- Wheel191
- Grease Seal192
- Axle192
- Wheel Bearing192
- Rear Wheel Coupling193
- Damper Inspection193
- Sprocket194
- Wear194
- Lubrication194
- Cleaning194
- Rear Sprocket Warp195
- Sprocket Teeth195
- Automatic Wear Adjustment195
- Brake195
- Braking Stroke196
- Braking Release Stroke196
- Master Cylinder197
- Front and Rear Master Cylinders197
- Master Cylinder Part Wear197
- Caliper198
- Pad Wear199
- Fluid Seal Damage199
- Front Brake Pad199
- Rear Brake Pad199
- Brake Disc200
- Dust Seal, Cover, O Ring Damage200
- Piston, Cylinder Wear200
- Disc Warp200
- Brake Fluid201
- Disc Cleaning201
- Changing the Brake Fluid202
- Bleeding the Brake202
- Steering203
- Brake Line Damage203
- Compression Stroke204
- Extension Stroke204
- Bearing Wear, Damage204
- Bearing Lubrication204
- Spring206
- Oil Seal, Dust Seal206
- Fork Oil206
- Lnner Tube206
- Fork Oil Level207
- Oil Level207
- Rear Shock Absorber207
- Bushing Inspection208
- Shock Absorber Spring Force208
- Swing Arm Bearing Wear209
- Swing Arm Lubrication209
- Pivot Shaft209
- Pivot Shaft Runout209
- Maintenance-Electrical210
- Battery211
- Hydrometer211
- Electrolyte211
- Specific Gravity/Battery Charge Relationship211
- Battery Troubleshooting Guide212
- Test Charging212
- Ordinary Charge212
- Initial Charge212
- Charging System213
- Initial Inspection213
- Alternator214
- Alternator Failure214
- Alternator Output Test214
- Stator Coil Resistance Check214
- Regulator/Rectifier215
- Diode Current Flow216
- Zener Diode216
- Thyristor216
- Basic Regulator/Rectifier Circuit216
- Regulator Test217
- Ignition System217
- Rectifier Inspection217
- Lgnition Coil218
- Coil Inspection218
- Lgnition Circuit218
- Lgnition Coil Test218
- Contact Breaker219
- Contact Breaker Inspection220
- Capacitor220
- Capacitor Inspection220
- Ignition Timing/Engine Speed Relationship220
- Inspection and Lubrication221
- Spark Plug221
- Starter Relay Test222
- Starter Motor Circuit222
- Electric Starter System222
- Starter Lockout Switch Test223
- Carbon Brushes223
- Starter Switch Test223
- Starter Motor Construction224
- Brush Spring224
- Starter Motor Clutch225
- Field Coils225
- Clutch Inspection226
- Testing the Switch226
- Starter Motor Clutch Operation226
- Lighting System227
- Switch Inspection227
- Headlight Circuit227
- Headlight Trouble228
- Tail Light Trouble228
- Brake Light Circuit229
- Rear Brake Light Switch Inspection229
- Front Brake Light Switch Inspection229
- Brake Light Failure Indicator Switch Inspection229
- Turn Signal Circuit231
- Turn Signal Trouble231
- Horn232
- Horn Construction232
- Horn Adjustment232
- Speedometer, Tachometer233
- Horn Current Measurement233
- Horn Trouble233
- Troubleshooting-Guide234
- Appendix238
- Additional Considerations for Racing239
- Spark Plug Reach240
- To Inspect the Spark Plugs240
- Special Tools241
- KZ500-B1 Wiring Diagram245
- Supplement for 1980 Model247
- Table of Contents247
Adjustment248
- Model Identification249
- KZ400-J1 (Right Side View)249
- KZ400-J1 (Left Side View)249
- Front Disc and Rear Drum Brake250
- Specifications251
SPECIFICATIONS (on KZ550)253
- Engine Performance Curves (on KZ400)255
  - KZ400-J1 (Except West German Model)255
  - KZ550-A1, C1 (US and Canadian Models)256
- Running Performance Curves (on KZ400)257
Engine Performance Curves (on KZ550)256
Running Performance Curves (on KZ550)258
- Periodic Maintenance Chart259
- CARBURETORS (on US Model)260
- Fuel System260
ADJUSTMENT CARBURETORS (on KZ400)260
KZ550-C] ADJUSTMENT IGNITION TIMING (on KZ550-C)260
FRONT FORK (on KZ550-C)261
REAR SHOCK ABSORBERS (on KZ550-C)261
- DRIVE CHAIN (with Rear Drum Brake)262
FRONT and REAR SUSPENSION SETTING (on KZ550-C)262
- BRAKES (on Rear Drum Brake)263
- GENERAL LUBRICATION (with Rear Drum Brake)264
Disassembly265
- Torque and Locking Agent265
- Fuel Tap265
- Carburetors265
- Mufflers266
- VACUUM SWITCH VALVE (on US Model)266
- AIR SUCTION VALVE (on US Model)267
- CY LINDER HEAD COVER (on US Model)267
- Supplement for 1980 Model 271268
CAMSHAFTS (on KZ400)268
CAMSHAFT SPROCKETS (on KZ400)268
- Carburetor Holders269
PISTON RINGS (on KZ400)269
ENGINE SPROCKET (on KZ400)269
STARTER MOTOR (on KZ550)269
Starter Motor (KZ550)270
Timing Advancer (on KZ550-C)271
- Engine Removal271
Front Wheel (on KZ550-C)272
- Front Disc Brake (on KZ550-C)273
- Front Brake Caliper (KZ550-C)274
- Rear Wheel, Rear Drum Brake275
TUBE LESS TI RES (on KZ550-C)278
Handlebar (on KZ550-C)280
Front Fork (on KZ550-C)280
- Throttle Cables280
- Front Fork (KZ550-C)281
Drive Chain (on KZ400)282
- Maintenance Carburetor283
- KAWASAKI CLEAN AIR SYSTEM (on US Model)283
  - Air Suction Valve284
  - Vacuum Switch Valve284
Swing Arm (on KZ550-C)282
Wheel (on KZ550-C)285
- Drive Chain289
- Drum Brake289
- Speedometer Gear Housing289
- Sprocket289
DISC BRAKE (on KZ550-C)291
FRONT FORK (on KZ550-C)291
- Inner Tube, Guide Bush292
- Fork Oil Level Measurement292
- Front Fork Load/Compression Stroke Replacement (Per each Fork Leg)292
- Front Fork Spring Force (Per each Fork Leg)293
Rear Shock Absorber (on KZ550-C)293
Pick-Up Coil294
Ignition System (on KZ550-C)294
- IC Igniter295
- Ignition System Troubleshooting Guide295
- Description of each Testing Procedure297
- Operational Inspection of the Lgnition System298
IGNITION SYSTEM (on KZ400)299
ELECTRIC STARTER SYSTEM (on KZ550)299
- LIGHTING SYSTEM (on US, Canadian Model)300
- Troubleshooting Guide301
Service Data for Kz400301
Service Data for Kz550301
- Specialtools302
- Wiring Diagrams302
  - KZ550-A1 Wiring Diagram303
  - KZ550-C1 Wiring Diagram304
  - Supplement for 1981 Model306
- Model Identification307
- Specifications309
- 1981 Model Main Changed Items313
- Periodic Maintenance Chart314
- Adjustment315
- Front Fork315
- Rear Shock Absorbers315
- BRAKE LIGHT SWITCHES (on KZ550D)315
- Disassembly316
- Clutch316
- Rear Master Cylinder and Reservoir317
- Rear Disc Brake317
- Torque and Locking Agent (on KZ550D)318
- Headlight318
- FUEL LEVEL SENDER (on KZ550C)318
- FUEL LEVEL SENDER (on KZ550D)319
- SHIFT PEDAL LINKAGE (on KZ550D)319
- Shift Pedal Linkage (on KZ550D)320
- OI L COOLER (on KZ550D)320
- FA1 LING (on KZ550D)321
- Headlight (on KZ550D)322
- TURN SIGNAL ASSY (on KZ550D)323
- Maintenance Cylinder Head Valve324
- Maintenance324
- Wheel325
- Discbrake325
- Front Fork326
- Rear Shock Absorbers326
- Swing Arm326
- Reserve Lighting System327
- MAINTENANCE AUTOMATIC TURN SIGNAL CANCE Lllng SYSTEM (on KZ550C)328
  - Distance Sensor Inspection329
  - Turn Signal and Selector Switch Inspection329
  - Carburetors (on KZ550D)330
  - Warning System Trouble330
- LOW FUEL WARN1 NG SYSTEM (on KZ550C)330
- Fuel Gauge (on KZ550D)331
- Appendix Specialtools333
- KZ400-J2/KZ500-B3/KZ550-A2/KZ550-B2 Wiring Diagram334
- Wiring Diagrams334
  - KZ550-A2 Wiring Diagram335
  - KZ550-C2 Wiring Diagram336
  - KZ550-D1 Wiring Diagram338
  - Index340

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Kawasaki KZ400 Specifications

General

Displacement	398cc
Compression ratio	9.0:1
Cooling system	Air-cooled
Fuel system	Carburetor
Ignition	Battery and coil
Transmission	5-speed
Front suspension	Telescopic fork
Front brakes	Single disc
Rear brakes	Drum
Final drive	Chain
Rear suspension	Dual shocks
Rear suspension details	Dual shocks, adjustable preload
Frame	Steel, double cradle