Kawasaki KZ400 (1974) [12/189] Running performance curves

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

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8 RUNNING PERFORMANCE CURVES Running Performance Curves 200 9000 8000 100 5000 4000 3000 2000 1000 100 Vehicle Speed Kph 120 140 160 Crankshaft rpm Driving Force Kg 150