ZXR400 Motorcycle Service Manual Supplement
Contents
1. a procedural step or work to be done Olndicates a procedural sub step or how to do the work of the procedural step it follows It also precedes the text of a WARNING CAUTION or NOTE Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub step it follows In most chapters an exploded view illustration of the system components follows the Table of Contents In these illustrations you will find the instructions indicating which parts require specified tightening torque oil grease or a locking agent during assembly MODEL APPLICATION Beginning Frame No ZX400L 000001 ZX400L 009001 ZX400L 020001 ZX400L 040001 ZX400L 045003 JKAZX400LLA060001 E E Kawasaki KAWASAKI HEAVY INDUSTRIES LTD Consumer Productu amp Machinery Group Part NO 99924 1140 53 Printed in Japan2. HE Kawasaki ZXR400 Motorcycle Service Manual Supplement Quick Reference Guide General Information Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Engine Removal Installation Crankshaft Transmission Wheels Tires Final Drive Brakes E Suspension 12 Steering oo By Frame 1g Electrical System 15E Appendix This quick reference guide will assist you in locating a desired topic or procedure Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page Refer to the sectional table of contents for the exact pages to locate the specific topic required Supplement 1999 Model Kawasaki ZXR400 Motorcycle Service Manual Supplement All rights reserved No parts of this publication may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Quality Assurance Department Consumer Products amp Machinery Group Kawasaki Heavy Industries Ltd Japan No liability can be accepted for any inaccuracies or omissions in this publication although every possible care has been taken to make it as complete and accurate as possible The
3. costly mistakes read the text thoroughly familiarize yourself with the procedures before starting work and then do the work carefully in a clean area Whenever special tools or equipment are specified do not use makeshift tools or equipment Precision measurements can only be made if the proper instruments are used and the use of substi tute tools may adversely affect safe operation For the duration of your warranty period especially we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty To get the longest life out of your Motorcycle Follow the Periodic Maintenance Chart in the Service Manual Be alert for problems and non scheduled mainte nance Use proper tools and genuine Kawasaki Motorcy cle parts Special tools gauges and testers that are necessary when servicing Kawasaki Motorcy cles are introduced by the Special Tool Manual Genuine parts provided as spare parts are listed in the Parts Catalog Follow the procedures in this manual carefully Don t take shortcuts Remember to keep complete records of mainte nance and repair with dates and any new parts installed How to Use this Manual In preparing this manual we divided the product into its major systems These systems became the manual s chapters All information for a particular
4. ed tools equipped if necessary with an appropriate dust extraction facility If high speed tools are used they should always be so equipped lf possible dampen before cutting or drilling Dampen dust and place it in properly closed receptacle and dispose of it safely Read OWNER S MANUAL before operating Foreword This ZX400L Service Manual Supplement is designed to be used in conjunction with the ZX400H Motorcycle Service Manual P N 99924 1137 01 The maintenance and repair procedures described in this supplement are only those that are unique to the ZX400L motorcycle Most service operation are described in the base Service Manual Complete and proper servicing of the ZX400L motorcycle therefore requires both this supplement and the base Service Manual The base Service Manual and this Supplement are designed primarily for use by trained mechanics in a properly equipped shop However they contain enough detail and basic information to make them useful to the owner who desires to perform his own basic maintenance and repair work A basic knowledge of mechanics the proper use of tools and workshop procedures must be understood in order to carry out maintenance and repair satisfac torily Whenever the owner has insufficient experi ence or doubts his ability to do the work all adjustments maintenance and repair should be carried out only by qualified mechanics In order to perform the work efficiently and to avoid
5. right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously See your Motorcycle dealer for the latest information on product improvements incorporated after this publication All information contained in this publication is based on the latest product information available at the time of publication Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts Kawasaki Heavy Industries Ltd 1991 1996 2000 Third Edition 1 Jan 20 2000 K LIST OF ABBREVIATIONS ampere s after bottom dead center alternating current after top dead center before bottom dead center bottom dead center before top dead center degree s Celsius direct current farad s degree s Fahrenheit foot feet gram s hour s liter s WARNING CONTAINS pound s meter s minute s newton s pascal s horsepower pound s per square inch revolution revolution s per minute top dead center total indicator reading volt s watt s ohm s This warning may apply to any of the following components or any assembly containing one or more of these components Brake Shoes or Pads Clutch Friction Material Gaskets Insulators SAFETY INSTRUCTIONS Operate if possible out of doors or in a well ventilated place Preferably use hand tools or low spe
6. system from adjustment through disassembly and inspection is located in a single chapter The Quick Reference Guide shows you all of the product s system and assists in locating their chapters Each chapter in turn has its own compre hensive Table of Contents The Periodic Maintenance Chart is located in the General Information chapter The chart gives a time schedule for required maintenance operations If you want spark plug information for example go to the Periodic Maintenance Chart first The chart tells you how frequently to clean and gap the plug Next use the Quick Reference Guide to locate the Electrical System chapter Then use the Table of Contents on the first page of the chapter to find the Spark Plug section Whenever you see these WARNING and CAUTION symbols heed their instructions Always follow safe operating and maintenance practices This Warning symbol identifies special instructions or procedures which if not correctly followed could result in personal injury or loss of life CAUTION This caution symbol identifies special instructions or procedures which if not strictly observed could result in damage to or destruction of equipment This manual contains four more symbols in addition to WARNING and CAUTION which will help you distinguish different types of information NOTE oThis note symbol indicates points of partic ular interest for more efficient and convenient operation ndicates
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