ZXR400 Motorcycle Service Manual Supplement
Contents
1. Engine Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum Torque Carburetion system Starting system Ignition system Timing advance Ignition timing Spark plug Cylinder numbering method 4 stroke DOHC 4 cylinder Liquid cooled 57 0 x 39 398 mL 12 1 47 8 KW 65 PS 13 000 r min rpm 36 3 N m 3 7 kg m 26 8 ft Ib 12 000 r min rpm Carburetor Keihin CVK D 32 4 Electric starter Battery and coil transistorized Electronically advanced From 12 5 BTDC 1 200 r min rpm to 45 BTDC 6 000 r min rpm NGK CR9EK or ND U27ETR Left to right 1 2 3 4 Firing order 1 2 4 3 Valve timing Inlet Open 23 BTDC Close 65 ABDC Duration 268 Exhaust Open 57 5 Close 27 5 Duration 265 Lubrication system Forced lubrication wet sump with cooler Engine oil Grade SE SF or SG class Viscosity SAE 10W 40 10W 50 20W 40 or 20W 50 Capacity 30L Drive Train Primary reduction system Type Gear Reduction ratio 2 195 90 41 SUPPLEMENT 1999 MODEL 17 5 Item ZX400 L9 Clutch type Wet multi disc Transmission Type 6 speed constant mesh return shift Gear 15 2 846 37 13 2 2 000 38 19 3rd 1 578 30 19 4th 1 318 29 22 5th 1 200 30 25 1 111 30 27 Final drive system Type Chain drive Reduction ratio 3 000 45 15 Overall drive ratio 7 317 Top gear Frame Type2. Press diamond Caster rake angle 23 5 Trail 82 mm Front tire Type TUBELESS Size 120 60 R17 55V Rear tire Type TUBELESS Size 160 60 R17 69V Front suspension Type Telescopic fork Wheel travel 120 mm Rear suspension Type Swingarm uni trak Wheel travel 120 mm Brake type Front Dual disc Rear Single disc Electrical Equipment Battery 12V8Ah Headlight Type Semi sealed beam Bulb Quartz halogen 12 V 60 55 W UK SG 12 V 60 35 W X 2 Tail brake light Alternator Type Rated output 12V5 21W X2 Three phase AC 23 A 210000 r min rpm 14 V Specifications are subject to change without notice and may not apply to every country SG Singapore Model UK U K Model KR Korea Model 17 6 SUPPLEMENT 1999 MODEL The scheduled maintenance must be done in accordance with this chart to keep the motorcycle in good running condition The initial maintenance is vitally important and must not be neglected OPERATION Spark plug clean and gap f Air cleaner element clean 4 Throttle grip play check T Idle speed check Idle speed adjust Carburetor synchronization check f Engine oil change Oil filter replace Radiator hoses connections check 7 Coolant change Clutch adjust Drive chain wear check Drive chain lubricate Drive chain slack check Brake lining or pad wear check Brake fluid level check T Brake fluid change 2 years Brake master cylinder cup
3. and dust seal replace 4 years Caliper piston seal and dust seal replace 4 years Brake light switch check f Steering check f Steering stem bearing lubricate 2 years Front fork change 2 years Rear shock absorber leak check Front fork oil leak check Tire wear check Swingarm pivot uni trak linkage lubricate General lubrication perform Nut bolt and fastener tightness check Coolant filter clean Service more frequently when operating in severe conditions dusty wet muddy high speed or frequent starting stopping For higher odometer readings repeat at the frequency interval established here Replace add adjust clean or torque if necessary SUPPLEMENT 1999 MODEL 17 7 Torque and Locking Agent Fastener Brakes Bleed valves Caliper Mounting Bolts Front Caliper Assembly Bolts Front Rear Pad Spring Screws Disc Mounting Bolt Front Rear Brake Hose Banjo Bolts Brake Lever Pivot Bolt Brake Lever Pivot Locknut Front Brake Light Switch Mounting Screw Brake Pedal Mounting Bolt Rear Master Cylinder Rod Locknut Caliper Mounting Bolts Rear Rear Master Cylinder Mounting Bolts Torque Link Bolt Torque Link Nut Fuel System Specifications Item Remarks Torque N m kg m ft Ib 7 8 0 80 69 in Ib 32 3
4. warning Light 12v2 Speed meter Lignt 12V1 Neutral indicator Lignt High Beam tor Lion Turn Signal Inalcaror Lion Headlignt 12 60 55 SUPPLEMENT 1999 MODEL 17 13 Fer DUES 17 44 SUPPLEMENT 1999 MODEL ZX400 L5 L6 L7 L8 Austria Dutch French Korea Models Tacnometer Liont 12V 011 Pressur SUPPLEMENT 1999 MODEL 17 15 17 16 SUPPLEMENT 1999 MODEL ZX400 L9 Wiring Diagram U K Model c ie owe d 1 1 L I T 17 T SUPPLEMENT 1999 MODEL 17 17 17 18 SUPPLEMENT 1999 MODEL ZX400 L9 Wiring Diagram Austria Dutch German German Greece Italy Models If LL E E SUPPLEMENT 1999 MODEL 17 19 Lee 1 TET in 22
5. 3 24 21 2 1 15 32 3 3 24 2 9 0 30 26 in Ib 27 2 8 20 23 23 17 25 2 5 18 1 0 0 10 9 in lb 5 9 0 60 52 in Ib 1 2 0 12 10 in Ib 34 3 5 25 18 1 8 13 25 2 5 18 23 2 3 17 25 2 5 18 25 2 5 18 Standard Throttle Grip Free Play 2 3mm Choke Cable Free Play 2 3mm Idle Speed 1300 50r min rpm IT UK NL GR 1200 50r min rpm Carburetor Specifications Make type Keihin CVK D32 Synchronization vacuum 2 7 kPa 2 cm Hg or less difference between two cylinders Main jet Standard 95 Option 90 92 98 100 Main air jet 100 Needle jet 6 Jet needle mark N 77W IT UK NL GR 77S Pilot jet slow jet 35 Pilot air jet 120 IT UK NL GR 110 Pilot screw 1 3 4 IT UK NL GR 1 58 Starter jet 45 Service fuel level 8 1 mm below the mark Float height 11 2mm Air Cleaner Air cleaner element oil Grade SE or SF class Viscosity SAE 30 IT Italia Model UK U K Model NL Netherlands Model GR Greece Model 17 8 SUPPLEMENT 1999 MODEL Wheels Tires Specifications Item Service Limit Wheels Rim runout Axial Radial Axle runout 100 mm 0 5 mm or less TIR 0 5 mm TIR 0 8 mm TIR 0 2 mm Tires Front Type Size Make Type Size Make Air pressure when cold Front Rear Tread depth Front Rear Tubeless 120 60 R17 55V BRIDGESTONE CYROX 7 Tubeless 160 60 R17 69V BRIDGESTONE CYROX 20 Up to 18
6. 5 kg 408 Ib load 225 kPa 2 25 kg 32 psi Up to 185 kg 408 Ib load 250 kPa 2 50 kg 36 psi 3 4 mm 5 8 mm under 130 km h 80mph over 130 km h 80mph Suspension Specifications Standard Service Limit Front Fork Rebound damping setting Spring preload setting Fork oil Viscosity Amount per side Oil level fully compressed with spring Fork spring free length 6 clicks counterclockwise front the seated position adjuster turned fully clockwise 6 th mark from the top SAE 5W 424 2 5 85 8 mm below from top of outer tube 325 1 mm adjustable range 12 clicks adjustable range 7 makes Rear Shock Absorber Rebound damping setting Spring preload setting Gas pressure SG Singapore Model No 2 of 4 position SG No 1 of 4 position Spring free length minus 6 5 mm 980 kPa 10 kg cm 142 psi Non adjustable Spring free length minus 6 5 mm to 24 5 mm SUPPLEMENT 1999 MODEL 17 9 17 10 SUPPLEMENT 1999 MODEL Greece Model SUPPLEMENT 1999 MODEL 17 11 Electrical System Specifications Item Standard Service Limit Ignition System Spark Plug Standard NGK CR9EK or ND U27 ETR Option ND U24 ETR 17 42 SUPPLEMENT 1999 MODEL Wiring Diagram Singapore Model Meter Liont 12v1 Tacnometer Tachometer Lignt 12V1 Oil Pressure
7. SUPPLEMENT 1999 MODEL 17 1 Supplement 1999Model Table of Contents Foreword General Information General Specifications Periodic Maintenance Chart Torque and Locking Agent Fuel System Specifications Wheels Tires Specifications Suspension Specifications Frame Exploded View Electrical System Specifications Wiring Diagram 17 2 17 3 17 4 17 6 17 7 17 7 17 7 17 8 17 8 17 8 17 8 17 9 17 9 17 11 17 11 17 12 17 2 SUPPLEMENT 1999 MODEL Foreword How to Use this Manual This Supplement 1999 Model designed to be used in conjunction with the front part of this manual up to 16 1 and or Base Manual ZX400H Service Manual Part No 99924 1137 01 The specifications and maintenance procedures described in this chapter are only those that are unique to the ZX400 L9 model Complete and proper servicing of the ZX400 L9 model therefore requires mechanics to read both this chapter and the front of this manual SUPPLEMENT 1999 MODEL 17 3 General Information 17 4 SUPPLEMENT 1999 MODEL General Specifications Item ZX400 L9 Dimensions Overall length Overall width Overall height Wheelbase Road clearance Seat height Dry weight Curb weight Front Rear Fuel tank capacity 1995 mm 700 mm 1 080 mm 1 385 mm 120 790 SG 760 162 kg SG 159 kg 95 kg SG KR 93 kg 93 kg SG 92 kg 16 0 L Performance Minimum turning radius 3 2m
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