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KZ400 (1974)
Инструкция по эксплуатации Страница: 1

Kawasaki KZ400 (1974) Инструкция по эксплуатации онлайн

1974

Содержание

Kz_400_1974 front cover 1
Shop manual 1
Decimal equivalents 2
Equivalents conversions 2
Kawasaki 4
Title page 4
Foreword 5
Adjustment 6
Contents1 6
Disassembly 6
Engine performance curves 6
Foreword 6
Maintenance theory of 6
Operation 6
Running performance curves 6
Specifications 6
Table of contents 6
Appendix 7
Contents2 7
Table of contents 3 7
Photos 8
Dimension 9
Specifications 9
Specifications 5 9
Electrical equipment 10
Specifications 10
Engine performance curves 11
Running performance curves 12
Adjustment 13
Adjustment 9 13
Carburetors 13
Preliminary adjustment 13
Preliminary checks 13
Throttle cables 13
Adjustmnet 14
Carburetor synchronization 14
Idling adjustment 14
Adjustment 11 15
Clutch 15
Adjustment 16
Ignition timing 16
Spark plugs 16
Adjustment 13 17
Adjustment 18
Valve clearance 18
Adjustment 15 19
Camshaft chain 19
Adjustment 20
Steering 20
Adjustment 17 21
Front brake lever 21
Rear brake 21
Wheel balance 21
Adjustment 22
Brake pedal position 22
Brake pedal travel 22
Cam lever angle 22
Adjustment 19 23
Brake light switch 23
Drive chain 23
Adjustment 24
Headlight 24
Horizontal adjustment 24
Rear shock absorbers 24
Adjustment 21 25
Vertical adjustment 25
Disassembly 26
Engine 26
Introduction to disassembly 26
Removal 26
Disassembly 23 27
Disassembly 28
Installation 28
Disassembly 25 29
Air cleaner element removal 30
Disassembly 30
Installation note 30
Oil filter removal 30
Assembly 31
Carburetors 31
Carburetors removal 31
Disassembly 31
Disassembly 27 31
Fuel tank removal 31
Installation 31
Installation per muffler 31
Mufflers removal per muffler 31
Disassembly 32
Installation 32
Assembly note 33
Assembly notes 33
Disassembly 33
Disassembly 29 33
Linkage mechanism and starter plunger unit 33
Rocker arms removal 33
Upper chamber and float chamber 33
Upper chamber and float chamber disassembly 33
Disassembly 34
Disassembly 31 35
Installation 35
Camshaft 36
Camshaft removal 36
Disassembly 36
Installation 36
Disassembly 33 37
Cylinder head removal 38
Disassembly 38
Disassembly 35 39
Installation 39
Disassembly 40
Disassembly 37 41
Valves valve guides removal per valve and valve guide 41
Disassembly 42
Cylinder block removal 43
Disassembly 39 43
Installation 43
Installation per valve and valve guide 43
Disassembly 44
Piston piston rings removal 44
Disassembly 41 45
Dynamo field coil 45
Dynamo field coil removal 45
Installation 45
Disassembly 46
Installation 46
Disassembly 43 47
Dynamo armature removal 47
Installation 47
Disassembly 48
Dynamo rotor starter 48
Installation 48
Motor clutch 48
Removal 48
Assembly note 49
Disassembly 45 49
Installation 49
Starter motor chain sprockets removal 49
Starter motor removal 49
Assembly notes 50
Disassembly 50
Condenser removal 51
Contact breaker removal 51
Disassembly 47 51
Ignition coil 51
Ignition coil removal 51
Installation note 51
Installation notes 51
Timing advancer removal 51
Assembly note 52
Clutch primary chain removal 52
Disassembly 52
Installation 52
Disassembly 49 53
Installation 53
Clutch release removal 54
Disassembly 54
Disassembly 51 55
Engine sprocket removal 55
Installation 55
Disassembly 56
Installation 56
Neutral indicator switch removal 56
Assembly note 57
Disassembly 57
Disassembly 53 57
Engine oil pump removal 57
External shift mechanism removal 57
Installation 57
Installation note 57
Disassembly 58
Disassembly 55 59
Transmission 59
Transmission removal 59
Disassembly 60
Disassembly 57 61
Installation 61
Disassembly 62
Disassembly 59 63
Shift drum disassembly 63
Disassembly 64
Disassembly 61 65
Drive shaft assembly notes 65
Drive shaft disassembly 65
Output shaft disassembly 65
Shift drum assembly notes 65
Disassembly 66
Installation notes 66
Kickstarter removal 66
Output shaft assembly notes 66
Assembly note 67
Disassembly 67
Disassembly 63 67
Installation note 67
Oil pressure relief valve removal 67
Balancer mechanism 68
Balancer mechanism removal 68
Disassembly 68
Installation 68
Assembly per balancer unit 69
Disassembly 65 69
Disassembly per balancer unit 69
Crankshaft camshaft chain removal 70
Disassembly 70
Disassembly 67 71
Installation 71
Disassembly 72
Disassembly 69 73
Assembly note 74
Assembly notes 74
Camshaft chain guide front removal 74
Camshaft chain guide rear removal 74
Disassembly 74
Disassembly 71 75
Front hub disassembly 75
Front wheel 75
Front wheel removal 75
Installation 75
Speedometer gear housing assembly notes 75
Speedometer gear housing disassembly 75
Disassembly 76
Front hub assembly notes 76
Rear wheel removal 76
Disassembly 73 77
Installation 77
Rear brake disassembly 77
Disassembly 78
Rear brake assembly 78
Disassembly 75 79
Installation 79
Rear hub assembly notes 79
Rear hub disassembly 79
Tire tube removal 79
Caution 80
Disassembly 80
Disc brake 80
Installation 80
Rim removal 80
Spoke breakage replacement 80
Caliper disassembly 81
Caliper removal 81
Disassembly 77 81
Disc installation note 81
Disc removal 81
Installation note 81
Pad installation 81
Pad removal 81
Caliper assembly 82
Disassembly 82
Master cylinder removal 82
Disassembly 79 83
Master cylinder disassembly 83
Master cylinder installation notes 83
Disassembly 84
Disassembly 81 85
Drive chain 85
Drive chain removal 85
Installation 85
Master cylinder assembly notes 85
Disassembly 86
Installation 86
Rear sprocket wheel coupling removal 86
Coupling assembly notes 87
Coupling disassembly 87
Disassembly 83 87
Handlebar removal 87
Clutch cable removal 88
Disassembly 88
Installation 88
Disassembly 85 89
Installation 89
Throttle cables removal 89
Disassembly 90
Installation 90
Installation note 90
Speedometer cable 90
Speedometer cable removal 90
Speedometer removal 90
Tachometer cable removal 90
Tachometer removal 90
Disassembly 87 91
Front fork removal left shock absorber 91
Headlight unit 91
Ignition switch removal 91
Indicator lights turn neutral oil removal 91
Installation 91
Installation note 91
Installation notes 91
Removal 91
Disassembly 92
Installation left shock absorber 92
Installation right shock absorber 92
Removal right shock absorber 92
Disassembly 89 93
Assembly 94
Disassembly 94
Steering stem 94
Steering stem removal 94
Disassembly 91 95
Installation 95
Disassembly 96
Installation 96
Steering stem bearing removal 96
Disassembly 93 97
Installation 97
Swing arm removal 97
Disassembly 98
Assembly notes 99
Disassembly 95 99
Installation both sides 99
Installation one side only 99
Rear shock absorbers removal one side only 99
Removal both sides 99
Air cleaner 100
Cleaning and replacement 100
Maintenance 100
Maintenance 97 101
Maintenance 102
Starter system 102
Cleaning 103
Cleaning and replacement 103
I ________ i 103
Maintenance 99 103
Pilot system 103
I ___________ i i 1 104
Main system 104
Maintenance 104
Cleaning and adjustment 105
Float system 105
Fuel level measurement and adjustment 105
Maintenance 101 105
Camshaft 106
Cleaning and replacement 106
Maintenance 106
Cam wear 107
Camshaft chain chain guides 107
Camshaft runout 107
Journal wear 107
Maintenance 103 107
Camshaft chain wear 108
Chain guide wear 108
Cylinder head valves 108
Maintenance 108
Rocker arm wear 108
Rocker arms shafts 108
Rocker shaft wear 108
Cleaning and inspection 109
Maintenance 105 109
Valve inspection 109
Valve valve guide valve seat 109
Maintenance 110
Valve guide inspection 110
Maintenance 107 111
Valve seat repair 111
Valve springs 111
Cylinder block pistons 112
Inspection 112
Maintenance 112
Oil seals 112
Compression measurement 113
Cylinder piston wear 113
Maintenance 109 113
Boring honing 114
Maintenance 114
Piston cleaning 114
Piston cylinder clearance 114
Piston cylinder seizure 114
Piston ring piston ring groove wear 114
Crankshaft con rods 115
Maintenance 111 115
Piston piston pin con rod wear 115
Piston ring end gap 115
Piston ring tension 115
Con rod bearing crankshaft journal wear 116
Con rod bend twist 116
Con rod side clearance 116
Maintenance 116
Balancer mechanism 117
Crankshaft bearing journal wear 117
Crankshaft runout 117
Maintenance 113 117
Oh passage cleaning 117
Balancer shaft holder wear 118
Maintenance 118
Chain guide wear 119
Chain wear 119
Clutch 119
Maintenance 115 119
Spring free length 119
Maintenance 120
Clutch plate warp 121
Clutch spring tension 121
Friction plate clutch housing clearance 121
Friction plate wear damage 121
Maintenance 117 121
Steel ring damage 121
Clutch housing drive shaft wear 122
Clutch housing sprocket damage 122
Clutch hub damage 122
Clutch release gear wear 122
Lubrication 122
Maintenance 122
Primary chain 122
Maintenance 119 123
Transmission 123
Maintenance 124
Externa shift mechanism inspection 125
Gear backlash 125
Maintenance 121 125
Shift fork bending 125
Shift fork gear groove wear 125
Ball bearing wear damage 126
Gear dog gear dog hole gear dog recess damage 126
Gear shaft wear 126
Kickstarter 126
Maintenance 126
Shift fork guide pin shift drum groove clearance 126
Shift fork guide pin shift drum groove wear 126
Engine lubrication 127
Kick gear shaft wear 127
Maintenance 123 127
2 kw i 128
M w c nt i av7 y 128
Maintenance 128
T im1 jj 128
Maintenance 125 129
Oh pressure indicator switch inspection 129
Oh pressure measurement 129
Relief valve wear 129
Engine oil pump 130
Maintenance 130
Oil filter 130
Outer rotor inner rotor clearance 130
Outer rotor pump body clearance 130
Relief valve spring tension 130
Rotor side wear 130
Fuel tank 131
Maintenance 127 131
Oil breather 131
Inspection and cleaning 132
Maintenance 132
Rim spokes 132
Tire wear damage 132
Wheels 132
Maintenance 129 133
Maintenance 134
Grease seals wheel bearings 135
Maintenance 131 135
Rim runout 135
Spoke breakage 135
Damper inspection 136
Drive chain 136
Inspection and lubrication 136
Maintenance 136
Rear wheel coupling 136
Lubrication 137
Maintenance 133 137
Sprocket wear 137
Sprockets 137
Disc brake 138
Maintenance 138
Rear sprocket warp 138
Maintenance 135 139
Brake fluid 140
Braking release stroke 140
Braking stroke 140
Maintenance 140
Bleeding the brake 141
Changing the brake fluid 141
Maintenance 137 141
Warning 141
Brake line damage 142
Caliper parts wear 142
Maintenance 142
Master cylinder parts wear 142
Brake drum wear 143
Disc wear warp 143
Maintenance 139 143
Rear brake 143
Brake shoe lining wear 144
Brake shoe spring tension 144
Camshaft shaft hole wear 144
Maintenance 144
Bearing lubrication 145
Bearing wear damage 145
Lubrication 145
Maintenance 141 145
Steering stem 145
Steering stem warp 145
Front fork 146
Maintenance 146
Compression stroke 147
Extension stroke 147
Fork oil 147
Maintenance 143 147
Maintenance 148
Spring tension 148
Bushings 149
Inner tube damage 149
Maintenance 145 149
Rear shock absorbers 149
Maintenance 150
Pivot shaft 150
Sleeve bush wear 150
Swing arm 150
Dynamo 151
Lubrication 151
Maintenance 147 151
Mufflers 151
Dynamo test 152
Maintenance 152
Maintenance 149 153
Inspection 154
Maintenance 154
Rectifier 154
Maintenance 151 155
Regulator 155
Maintenance 156
Regulator testing 156
Maintenance 153 157
Battery 158
Maintenance 158
0 007 t 20 159
10 004 t 68 159
Celcius 159
Electrolyte 159
Fahrenheit 159
Generally speaking a battery should be charged if a 159
Given below should be used to compute what the specific gravity would be if the temperature were 20 c 68 f when the temperature goes up the specific gravity goes down and vice versa 159
Last a few years but it may be completely ruined long before that if it is mistreated following a few simple rules will greatly extend the life of the battery 159
Maintenance 155 159
Specific gravity at 20 c 159
Specific gravity at 68 f t present temperature of solution 159
Specific gravity at the present temperature 159
Specific gravity of the electrolyte used in warm climates in a fully charged battery is 1 60 at 20 c 68 f in particularly cold regions a solution with a standard specific gravity of 1 80 is used the water in this solution changes to a gaseous mixture due to chemical action in the battery and escapes which concentrates the acid in a charged battery consequently when the level of the electrolyte becomes low only distilled water should be added if sulphuric acid is added the solution will become too strong for proper chemical action and will damage the plates metal from the damaged plates collects in the bottom of the battery this sediment will eventually cause an internal short circuit 159
Specific gravity reading shows it to be discharged to 50 or less of full charge 159
The electrolyte is dilute sulphuric acid the standard 159
The specific gravity of the electrolyte is measured 159
With a hydrometer and is the most accurate indication of the condition of the battery when using the hydrom eter read the electrolyte level at the bottom of the meniscus curved surface of the fluid fig 534 shows the relationship between the specific gravity of the solution at 20 c 68 f and the percentage of battery charge since specific gravity varies with temperature and since the temperature of the solution being checked is likely to be other than 20 c 68 f the formula 159
With proper care the battery can be expected to 159
Initial charge 160
Maintenance 160
Ordinary charge 160
Test charging 160
Contact breaker inspection 161
Ignition system 161
Maintenance 157 161
Condenser inspection 162
Ignition coil inspection 162
Maintenance 162
Inspection and lubrication 163
Maintenance 159 163
Spark plugs 163
Timing advancer 163
Inspection and replacement 164
Maintenance 164
Starter motor circuit 164
Carbon brushes 165
Commutator 165
Maintenance 161 165
Field coils 166
Maintenance 166
Maintenance 163 167
Starter motor clutch chain 167
Starter relay 167
Clutch inspection 168
Headlight circuit 168
Headlight trouble 168
Ignition switch 168
Maintenance 168
Starter chain inspection 168
Testing the switch 168
Brake light circuit 169
Maintenance 165 169
Tail light trouble 169
Brake light circuit trouble 170
Maintenance 170
Maintenance 167 171
Turn signal trouble 171
Turn signals 171
Horn trouble 172
Maintenance 172
Speedometer tachometer 172
Appendix 173
Appendix 169 173
Special tools 173
Appendix 174
Appendix 171 175
Periodic maintenance 176
Appendix 173 177
Engine oil change 177
Fuel line cleaning 177
General lubrication 177
Appendix 178
Appendix 182
Engine doesn t start starting difficulty 182
Poor running at low speed 182
Poor running or no power at high speed 182
Troubleshooting 182
Troubleshooting guide 182
Abnormal drive train noise 183
Abnormal engine noise 183
Appendix 179 183
Clutch operation faulty 183
Gear shifting faulty 183
Overheating 183
Abnormal frame noise 184
Appendix 184
Battery discharged 184
Battery overcharged 184
Brakes don t hold 184
Exhaust smoke 184
Handling and or stability unsatisfactory 184
Oil pressure indicator light goes on 184
Wiring diagram 185
Index 183 187
Rear cover 189

Kawasaki KZ400 (1974) Инструкция по эксплуатации онлайн

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