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Kawasaki ZXR400 - User Manual

Kawasaki ZXR400
141 pages
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Table of Contents

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Summary

General Information

Model Identification

Identifies specific model variants and their characteristics for accurate service.

General Specifications

Provides key technical data, dimensions, and performance metrics for the motorcycle.

Periodic Maintenance Chart

Outlines recommended maintenance intervals and tasks based on mileage or time.

Torque and Locking Agent

Lists torque values and recommended locking agents for various fasteners.

Fuel System

Exploded View

Visual diagram showing all fuel system components and their assembly order.

Specifications

Details specifications for carburetor settings, jets, and other fuel system components.

Special Tools

Lists specialized tools required for fuel system servicing and adjustments.

Carburetor Installation

Step-by-step instructions for installing carburetors and related components.

Cooling System

Exploded View

Visual diagram showing all cooling system components and their assembly order.

Specifications

Provides specifications for coolant type, capacity, radiator cap pressure, and thermostat.

Special Tool

Identifies specialized tools for cooling system maintenance.

Engine Top End

Exploded View

Visual diagram of the engine's top end components and their assembly.

Specifications

Detailed specifications for camshafts, valves, pistons, and cylinders.

Special Tools

Lists specialized tools needed for engine top end servicing.

Clutch

Exploded View

Visual diagram of clutch components and their order of assembly.

Specifications

Provides specifications for clutch lever play, plate thickness, and spring length.

Special Tool

Identifies specialized tools for clutch maintenance.

Engine Lubrication System

Exploded View

Visual diagram of the engine lubrication system components and their assembly.

Engine Oil Flow Chart

Illustrates the path of engine oil throughout the lubrication system.

Specifications

Details specifications for engine oil type, viscosity, capacity, and oil pressure.

Engine Removal; Installation

Exploded View

Visual diagram of the frame and engine mounting points.

Special Tool

Identifies specialized tools for engine removal and installation.

Crankshaft; Transmission

Exploded View

Visual diagram of crankshaft and transmission components.

Specifications

Details specifications for connecting rods, crankshaft, and transmission gear ratios.

Special Tools

Lists specialized tools required for crankshaft and transmission servicing.

Crankcase

Notes and diagrams related to crankcase assembly.

Wheels; Tires

Exploded View

Visual diagram of wheel and tire components and their assembly.

Specifications

Provides specifications for wheel dimensions, tire sizes, and pressure.

Special Tools

Lists specialized tools required for wheel and tire servicing.

Final Drive

Exploded View

Visual diagram of final drive components and their assembly.

Specifications

Details specifications for drive chain type, slack, and related adjustments.

Drive Chain

Information on drive chain, including slack adjustment procedures.

Wheel Alignment and Drive Chain Maintenance

Covers wheel alignment, drive chain wear inspection, and lubrication procedures.

Brakes

Exploded View

Visual diagram of brake system components and their assembly.

Specifications

Provides specifications for brake fluid, lever play, pad thickness, and disc runout.

Special Tools

Identifies specialized tools required for brake maintenance.

Suspension

Exploded View

Visual diagram of front fork and rear shock absorber components.

Specifications

Technical details for front fork and rear shock absorber settings and dimensions.

Special Tools

Lists specialized tools required for suspension maintenance.

Front Fork Maintenance Procedures

Step-by-step guide for fork oil change, disassembly, inspection, and spring tension.

Steering

Exploded View

Visual diagram of steering system components and their assembly.

Special Tools

Lists specialized tools for steering system servicing.

Frame

Exploded View

Visual diagram of the motorcycle frame and its associated parts.

Electrical System

Precautions

Important safety precautions for working with the electrical system.

Exploded View

Visual diagram of electrical system components and their assembly.

Specifications

Details specifications for battery, ignition, charging system, and lights.

Wiring Diagram

Comprehensive wiring diagrams for diagnosing and repairing electrical issues.

Appendix

Troubleshooting Guide

Provides guidance on identifying and fixing common motorcycle problems.

Component Information

Details on carburetor and spark plug inspection procedures.

Fastener Tightness

Specific torque values for various fasteners not covered elsewhere.

Unit Conversion Table

Table for converting between different measurement units (e.g., metric to imperial).

Supplement - 1999 Model

General Specifications

Provides specific dimensions, performance, and engine specifications for the 1999 model.

Periodic Maintenance Chart

Outlines recommended maintenance intervals and tasks for the 1999 model.

Torque and Locking Agent

Lists torque values and recommended locking agents for 1999 model fasteners.

Component Specifications

Specifications for wheels, tires, and suspension components relevant to the 1999 model.

Kawasaki ZXR400 Specifications

General IconGeneral
Final DriveChain
Front Tire120/60-17
Rear Tire160/60-17
Engine TypeLiquid cooled, 4 stroke, transverse four cylinder, DOHC, 4 valves per cylinder
Transmission6-speed
Fuel SystemCarburetor
IgnitionDigital
FrameAluminum perimeter
Front SuspensionTelescopic fork
Rear SuspensionUni-Trak
Front BrakesDual disc
Rear BrakesSingle disc
Height1, 100 mm
Seat Height770 mm

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