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Kawasaki KZ400 - Service Manual

Kawasaki KZ400
342 pages
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Kawasaki
Motorcycle
Service
Manual
Kawasaki Heavy Industries, Ltd. 1979, 1980, 1981
Revised
2:
Feb. 17, 1981
@

Table of Contents

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Summary

Foreword

Manual Structure Overview

Outlines the manual's main sections including Adjustment, Disassembly, Maintenance, Appendix, and Supplement.

Quick Reference Guide

Section Navigation

Provides a quick reference to all major sections (A-P) for easy navigation.

Model Identification

Motorcycle Views

Displays side views of the KZ500-B1 for model identification.

Specifications

Key Specifications and Charts

Lists core technical data, performance curves, and the periodic maintenance chart.

Engine Adjustment

Spark Plugs, Ignition Timing, and Valve Clearance

Covers spark plug inspection, gap adjustment, and ignition timing tests.

Carburetor, Engine Oil, and Fuel System

Details adjustments and maintenance for carburetors, engine oil, and the fuel system.

Chassis Adjustment

Suspension, Brakes, and Steering

Covers adjustments for rear shock absorbers, drive chain, brakes, and steering system components.

Wheel Balance, Headlight, and Lubrication

Explains wheel balancing, headlight aiming, and general chassis lubrication procedures.

Disassembly Introduction

General Disassembly Guidelines and Torque Specs

Provides essential precautions and general rules for motorcycle disassembly.

Engine Disassembly (Installed)

Major Component Removal

Details the removal of fuel tank, fuel tap, air cleaner, carburetors, mufflers, and ignition coils.

Internal Engine Component Disassembly

Covers disassembly of camshafts, sprockets, cylinder head, valves, pistons, and rings.

Engine Disassembly (Removed)

Engine Removal and Crankcase Split

Outlines the procedure for removing the engine from the frame and splitting the crankcase.

Transmission and Crankshaft Disassembly

Details the disassembly of transmission gears, shafts, crankshaft, and connecting rods.

Chassis Maintenance

Wheel, Brake, and Tire Maintenance

Covers maintenance for wheels, tires, rims, disc brakes, and fluid replacement.

Front Fork and Steering System Maintenance

Details maintenance procedures for the front fork, steering stem, and bearings.

Rear Shock Absorbers and Swing Arm Maintenance

Explains maintenance for rear shock absorbers, swing arm, and drive chain systems.

Engine Maintenance

Air Cleaner, Fuel System, and Carburetor Maintenance

Covers cleaning and maintenance of air cleaner, fuel system, and carburetor components.

Camshaft, Cylinder Head, and Valve Maintenance

Details inspection and maintenance for camshafts, cylinder heads, valves, and seats.

Piston, Cylinder, and Crankshaft Maintenance

Covers inspection and maintenance of pistons, cylinders, crankshafts, and connecting rods.

Engine Lubrication System Maintenance

Explains the engine oil system, pressure checks, oil pump, filter, and breather maintenance.

Troubleshooting Guide

Engine Performance and Starting Issues

Addresses common problems related to engine starting, running, compression, and performance.

Chassis, Electrical, and Handling Issues

Covers troubleshooting for chassis, electrical systems, handling, stability, and brakes.

Appendix

Special Tools and Wiring Diagrams

Lists special tools required for service and provides essential wiring diagrams for troubleshooting.

1980 Model Supplement

Model Identification and Specifications

Identifies 1980 models and lists their key specifications.

1980 Model Maintenance and Adjustments

Details adjustments and maintenance specific to 1980 models, including carburetors and suspension.

1980 Model Disassembly Procedures

Outlines disassembly steps for 1980 model variations, including engine and chassis components.

1981 Model Supplement

1981 Model Main Changed Items

Highlights key modifications and updates for 1981 motorcycle models compared to previous years.

1981 Model Adjustments and Maintenance

Details adjustments for front fork, rear shocks, and maintenance for brakes, headlights, and fuel systems on 1981 models.

1981 Model Disassembly Procedures

Covers disassembly of clutch, rear disc brake, fuel level sender, and shift linkage for 1981 models.

Summary

Foreword

Manual Structure Overview

Outlines the manual's main sections including Adjustment, Disassembly, Maintenance, Appendix, and Supplement.

Quick Reference Guide

Section Navigation

Provides a quick reference to all major sections (A-P) for easy navigation.

Model Identification

Motorcycle Views

Displays side views of the KZ500-B1 for model identification.

Specifications

Key Specifications and Charts

Lists core technical data, performance curves, and the periodic maintenance chart.

Engine Adjustment

Spark Plugs, Ignition Timing, and Valve Clearance

Covers spark plug inspection, gap adjustment, and ignition timing tests.

Carburetor, Engine Oil, and Fuel System

Details adjustments and maintenance for carburetors, engine oil, and the fuel system.

Chassis Adjustment

Suspension, Brakes, and Steering

Covers adjustments for rear shock absorbers, drive chain, brakes, and steering system components.

Wheel Balance, Headlight, and Lubrication

Explains wheel balancing, headlight aiming, and general chassis lubrication procedures.

Disassembly Introduction

General Disassembly Guidelines and Torque Specs

Provides essential precautions and general rules for motorcycle disassembly.

Engine Disassembly (Installed)

Major Component Removal

Details the removal of fuel tank, fuel tap, air cleaner, carburetors, mufflers, and ignition coils.

Internal Engine Component Disassembly

Covers disassembly of camshafts, sprockets, cylinder head, valves, pistons, and rings.

Engine Disassembly (Removed)

Engine Removal and Crankcase Split

Outlines the procedure for removing the engine from the frame and splitting the crankcase.

Transmission and Crankshaft Disassembly

Details the disassembly of transmission gears, shafts, crankshaft, and connecting rods.

Chassis Maintenance

Wheel, Brake, and Tire Maintenance

Covers maintenance for wheels, tires, rims, disc brakes, and fluid replacement.

Front Fork and Steering System Maintenance

Details maintenance procedures for the front fork, steering stem, and bearings.

Rear Shock Absorbers and Swing Arm Maintenance

Explains maintenance for rear shock absorbers, swing arm, and drive chain systems.

Engine Maintenance

Air Cleaner, Fuel System, and Carburetor Maintenance

Covers cleaning and maintenance of air cleaner, fuel system, and carburetor components.

Camshaft, Cylinder Head, and Valve Maintenance

Details inspection and maintenance for camshafts, cylinder heads, valves, and seats.

Piston, Cylinder, and Crankshaft Maintenance

Covers inspection and maintenance of pistons, cylinders, crankshafts, and connecting rods.

Engine Lubrication System Maintenance

Explains the engine oil system, pressure checks, oil pump, filter, and breather maintenance.

Troubleshooting Guide

Engine Performance and Starting Issues

Addresses common problems related to engine starting, running, compression, and performance.

Chassis, Electrical, and Handling Issues

Covers troubleshooting for chassis, electrical systems, handling, stability, and brakes.

Appendix

Special Tools and Wiring Diagrams

Lists special tools required for service and provides essential wiring diagrams for troubleshooting.

1980 Model Supplement

Model Identification and Specifications

Identifies 1980 models and lists their key specifications.

1980 Model Maintenance and Adjustments

Details adjustments and maintenance specific to 1980 models, including carburetors and suspension.

1980 Model Disassembly Procedures

Outlines disassembly steps for 1980 model variations, including engine and chassis components.

1981 Model Supplement

1981 Model Main Changed Items

Highlights key modifications and updates for 1981 motorcycle models compared to previous years.

1981 Model Adjustments and Maintenance

Details adjustments for front fork, rear shocks, and maintenance for brakes, headlights, and fuel systems on 1981 models.

1981 Model Disassembly Procedures

Covers disassembly of clutch, rear disc brake, fuel level sender, and shift linkage for 1981 models.

Kawasaki KZ400 Specifications

General IconGeneral
Displacement398cc
Compression ratio9.0:1
Cooling systemAir-cooled
Fuel systemCarburetor
IgnitionBattery and coil
Transmission5-speed
Front suspensionTelescopic fork
Front brakesSingle disc
Rear brakesDrum
Final driveChain
Rear suspensionDual shocks
Rear suspension detailsDual shocks, adjustable preload
FrameSteel, double cradle

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