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ZXR400 Motorcycle Service Manual Supplement
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1. Front fork oil change 1 6 GENERAL INFORMATION Whichever mm ODOMETER READING FREQUENCY comes first OPERATION Tire wear check Swing arm pivot uni trak linkage lubricate General lubrication perform Nut bolt and fastener tightness check Coolant filter B clean For higher odometer readings repeat at the frequency interval established here Replace add adjust clean or torque if necessary GENERAL INFORMATION 1 7 Technical Information Maintenance Free Battery A maintenance free battery is installed in this model The maintenance free battery is a sealed type and so the electrolyte I Construction Sealing plug Lid P P Terminal lead calcium alloy Filter Safety valve Filler plug Pole lead calcium alloy Negative plate lead and lead calcium alloy Special separator Positive plate lead and lead calcium alloy II Main Features 1 Maintenance free It is not necessary to check the electrolyte level and top off the electrolyte As the electrolyte is retained firmly in the special separators there is no free electrolyte in the battery It can be used instantly after filling only the electrolyte without initial charge It is possible to fill the electrolyte by easy one push motion If the battery internal pressure rises abnormally high the safety valve opens t
2. numbering method 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 BBDC Close 27 5 ATDC 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 3 0L Drive Train Primary reduction system Type Gear Reduction ratio 2 195 90 41 1 4 GENERAL INFORMATION Items ZX400 L1 15 Clutch type Wet multi disc Transmission Type 6 speed constant mesh return shift Gear ratios 1st 2 846 37 13 2nd 2 000 38 19 3rd 1 578 30 19 4th 1 318 29 22 5th 1 200 30 25 6th 1 111 30 27 Final drive system Type Chain drive Reduction ratio 3 000 45 15 Overall drive ratio 7 317 Top gear Frame Type Press diamond Caster rake angle 23 5 Trail 82 mm Front tire Size type 120 60 VR17 FG 120 60 ZR17 TUBELESS Mark DUNLOP D202FA BRIDGESTONE CYROX 17 Rear tire Size type 160 60 VR17 FG 160 60 ZR17 TUBELESS Mark DUNLOP D202A BRIDGESTONE CYROX 20 Front suspension Type Telescopic fork Wheel travel 120 mm Rear suspension Type Swingarm uni trak Wheel travel 120 mm Brake type Front Dual discs Rear Single disc Electrical Equipment Battery 12V8Ah Headlight Type Semi sealed beam Bulb Quartz halogen 12 V 60 55 W UK 12 V 60 35 W x 2 Tail brake light 12V 5 21 Wx2 Alternator Type Three phase AC Rated outpu
3. Fork Clamp Bolts Upper Frame Step Holder Mounting Bolts Side Stand Bracket Bolts Electrical Starter Motor Clu Spark Plugs i Pickup Coil Cover Bolts y L one bolt only Timing Check Plug hand tight Pickup Coil Bolt Timing Rotor Allen Bolts Alternator Alternator Cover Bolts Alternator Rotor Bolt Alternator Stator Allen Bolt Alternator Stator Lead Clamp Bolt Alternator Cover Mating Surfaces Starter Motor Mounting Bolts Starter Motor Clutch Allen Bolt Battery Ground Lead Bolt Crankcase Tail Lamp Mounting Nuts Cooling Fan Switch Water Temperature Sensor Oil Pressure Switch Neutral Switch 1 14 GENERAL INFORMATION Cable Wire and Hose Routing 26 8 s 24 25 30 31 32 33 34 35 36 Headlight Lead Headlight Lead U K Model Left Turn Signal Light Leads Front Right Turn Signal Light Leads Front Cooling Fan Switch Lead Water Temperature Sensor Lead Side Stand Switch Lead Fuel Pump Lead Regulator Lead Headlight Relay Lead U K Model Battery Alternator Lead Starter Motor Lead Starter Relay Fuel Pump Relay IC Igniter Left Tum Signal Light Leads Rear Tail Brake and License Lights Lead Right Turn Signal Light Leads Rear Turn Signal Relay Battery Lead Pickup Coil Lead Connector Junction Box Rear Brake Light Switch Lead Engine Ground Terminal Oil Pressure Switch Lead Neut
4. GENERAL INFORMATION 1 1 General Information Table of Contents Before Servicing Model Identification General Specifications Periodic Maintenance Chart Technical Information Torque and Locking Agent Cable Wire and Hose Routing Refer to Base Manual 1 1 2 GENERAL INFORMATION Model Identification ZX400 L1 Left Side View ZX400 L1 Right Side View General Specifications GENERAL INFORMATION 1 3 Item ZX400 L1 L5 Dimensions Overall length 1 195 mm FG NR GR SD 2 090 mm Overall width 700 mm Overall height 1080 mm Wheelbase 1385 mm Road clearance 120 mm Seat height 760 mm Dry weight 159 kg Curb weight Front 93 kg Rear 92 kg Fuel tank capacity Performance Minimum turning radius Engine Type Cooling system Bore and stroke Displacement Compression ratio Maximum horsepower Maximum Torque Carburetion system 16 0L 4 stroke DOHC 4 cylinder Liquid cooled 57 0 X 39 0mm 398 mL 12 1 47 8 kW 65 PS 13 000 r min rpm UTAC s norm FR 46 4 kW PS 13 000 r min rpm 36 3 N m 3 7 kg m 26 8 ft lb 12 000 r min rpm Carburetor Keihin CVK D32 X 4 Starting system Electric starter Ignition system Battery and coil transistorized Timing advance Electronically advanced Ignition timing From 12 5 BTDC 1 200 r min rpm to 45 BTDC 6 000 r min rpm Spark plug NGK CR9EK or ND U27ETR Cylinder
5. Mounting Bolt Chain Tensioner Lock Bolt Rocker Shaft Plug Upper Chain Guide Bolt Inlet Pipe Mounting Bolt carburetor holder Outlet Pipe Mounting Bolt cylinder head Camshaft Cap Bolts Cylinder Head Bolts 8mm 6mm Muffler Body Mounting Nuts Clutch Cover Bolts Clutch Cover Damper Bolts Clutch Hub Nut Clutch Spring Bolts Engine Drain Plug 26 in Ib 78 in lb L two bolts L R 1 12 GENERAL INFORMATION Brake Lever Pivot Bolt Fastener Torque Remarks N m kg m ft lb Oil Hose Mounting Bolt cylinder head crankcase 98 1 0 7 0 Oil Filter 9 8 or 1 0 or 7 0 or hand tight hand tight hand tight Oil Filter Mounting Bolt 29 30 22 Oil Pressure Relief Valve 15 15 11 0 L Oil Filler Cap 15 0 15 13 in Ib hand tight Oil Pressure Switch Terminal 15 015 13 in Ib Oil Pressure Switch 15 15 110 ss Oil Pump Cover Screws 44 0 5 43 in Ib Oil Plug Right M18 15 1 5 11 0 Oil Cooler Pipe Fitting Bolt 12 12 8 5 Oil Cooler Screen Mounting Screw 49 0 5 43 in Ib Oil Pan Bolts 98 10 7 0 Engine Removal Installation Engine Bracket Mounting Bolts 25 25 18 0 Engine Mounting Bolts 44 45 33 Engine Mounting Nuts 44 45 33 Crankshaft Transmission Shift Drum Cam Mounting Bolts 12 12 85 L Shift Drum Set Lever Bolt 98 10 70 Shift Drum Bearing Retainer Bolt 12 12 85 Shift Return Spring Bolt 20 2 0 145 L Neutral Switch 15 15 110 Breather Plate Mating Surfaces SS Brea
6. ecompose electrolytically water from the electrolyte thus resulting in generation of hydrogen gas from the negative plate and oxygen 1 8 GENERAL INFORMATION gas from the positive plate The gases so generated are released out of the battery causing the amount of electrolyte decreased to require occasional water replenishment A maintenance free battery however is so designed that when it is overcharged even if the positive plate is fully charged the negative plate remains not fully turned to spongy lead Therefore even when the positive plate is overcharged generating oxygen gas the negative plate is not fully charged hence generating no hydrogen gas Moreover the oxygen gas generated from the positive plate immediately reacts with the charged active material on the negative plate and returns to water with the ultimate result of no water loss Pb 1 202 gt PbO Negative active Oxygen generated Negative active material from positive plate material charged state PbO 2504 gt PbSO H20 Electrolyte Negative active Water material charged state Thus the negative plate is made as not to get fully charged Even if the overcharge continues the oxygen gas generated inside the battery is absorbed by the negative plate a process called oxygen cycle which theoretically prevents water loss and allows the battery to be sealed IV Filling the Battery with Electrolyte Do not remove the aluminum seal sheet sea
7. ing sound Shoosh as you removed the seal Battery as old as 2 years or more after manufacture Battery manufacturing date is printed on battery top Example 12 10 90 n Day Month Year Mfg location Note 1 Terminal voltage To measure battery terminal voltage use a digital voltmeter 0 9 A x 15 20 hours 1 10 GENERAL INFORMATION VI Precautions 1 No need of topping up No topping up is necessary in this battery until it ends its life under normal use Forcibly prying off the sealing plug to add water is very dangerous Never do that 2 Refreshing charge If an engine will not start a horn sounds weak or lamps are dim it indicates the battery has been discharged Give refresh charge for 5 to 10 hours with charge current shown in the specification see the Electrical System chapter When a fast charge is inevitably required do it following precisely the maximum charge current and time conditions indicated on the battery CAUTION This battery is designed to sustain no unusual deterioration if refresh charged accordi However the batterys performance may be reduced noticeably if charged under conditions other than given above Never remove the sealing plug during refresh charge If by chance an excessive amount of gas is generated due to overcharging the safety valve operates to keep the battery safe 3 When you do not use the motorcycle for months Give a refresh charge before you store
8. ling the filler ports until just before use Be sure to use the dedicated electrolyte container for correct electrolyte volume Check to see that there is no peeling tears or holes in the sealing sheet Place the battery on a level surface Remove the sealing sheet OWhen removing check to hear an air sucking sound 1 Strip of Caps 3 Container Shoosh from filler ports 2 Sealed Areas NOTE 6 Place the electrolyte container upside down with the six M sealed areas in line with the six battery filler ports OA battery whose sealing sheet has any peeling teers Push the container down strongly enough to break the holes or from which the alr sucking sound was not seals Now the electrolyte should start to flow into the heard requires a refreshing charge initial charge battery NOTE O Do not tilt the container as the electrolyte flow may be interrupted O 1 Sealing Sheet 2 Filler Ports Take the electrolyte container out of the vinyl bag Detach the strip of caps from the container NOTE O Do not discard the strip of caps because it is used as the battery plugs later i i Make sure air bubbles are coming up from all six filler O Do not peel back or pierce the sealed areas pore O Leave the container this way for 5 minutes or longer GENERAL INFORMATION 1 9 NOTE Now pull the container gently out of the battery Olf no air bubbles are coming up f
9. o release the gas inside the battery to restore the normal pressure and prevent the battery from rupturing After restoring the normal pressure the safety valve closes and the battery is sealed again Moreover a ceramic filter is disposed on top of the safety valve under the lid to remove risk of ignition or explosion caused by fire from outside No presence of free electrolyte allows the battery made lower in height thus resulting in enhanced volume efficiency Moreover gas being absorbed inside the battery eliminates the need for a gas exhaust tube It can amply withstand deep charge discharge cycles 2 No electrolyte leakage 3 Instant activation system 4 One push motion electrolyte filling 5 Safety construction 6 Compact and high performance 7 Strong charge discharge characteristics III Principle of Sealing Structure A lead acid battery operates under the following chemical reaction Discharge PbOz 2H2S04 Pb PbSOs 2H20 PbSO4 Lead peroxide Sulfuric acid Spongy lead Charge Lead sulfate water Lead sulfate Positive active Electrolyte Negative active Positive active Electrolyte Negative active material material material material Normally in an ordinary lead acid battery when it comes to an end of a charge where the lead sulfate being a discharge product returns to lead peroxide and spongy lead the charge current flowing thereafter is used exclusively to d
10. ral Switch Lead Meters Leads Horn Lead Ignition Switch Lead Left Handlebar Switch Lead Cooling Fan Motor Lead Right Handlebar Switch Lead Ignition Coil Leads Main Harness Stator Coil Lead GENERAL INFORMATION 1 15 37 Clamp 42 Speedometer Cable 38 Band 43 Cooling Fan Switch 39 Front Fender 44 Radiator 40 Hom 45 Headlight Relay U K Model 41 Brake Hose Joint 46 Regulator 1 16 GENERAL INFORMATION Front gt 89 47 Front Brake Hose 48 Throttle Cable 49 Clutch Cable 50 Coolant Reservoir Tank 51 Coolant Reservoir Tank Hose 52 Reservoir Tank Overflow Hose 53 Green Lead 54 Red Leads 55 Black Lead 56 Ignition Coil 42 43 57 Ignition Coil 41 4 58 Choke Cable 59 Spark Plugs
11. rom a filler port tap the Let the battery sit for 20 minutes During this time the n electrolyte permeates the special separators and the gas bottom of the bottle two or three times Never remove jenerated by chemical fon le rel the container from the battery g leased Fit the strip of caps tightly into the filler ports until the strip is at the same level as the top of the battery NOTE ODo not hammer Press down evenly with both hands CAUTION Once you install the strip of caps after filling the battery never remove it nor add any water or electrolyte 1 Air Bubble 2 Tap Be certain that all the electrolyte has flowed out Tap the bottom the same way as above if there is any electrolyte left in the container 1 Strip of Caps V Initial Charge While a maintenance free battery can be used after only filling with electrolyte a battery may not be able to sufficiently move a starter motor to start an engine in the cases shown in the table below where an initial charge is required before use However if a battery shows a terminal voltage of higher than 12 5 V after 10 minutes of filling Note 1 no initial charge is necessary Condition requiring initial charge Charging method At low temperatures lower than 0 C 09 A x 2 3 hours Battery has been stored in high temperature and humidity Seal has been removed or broken peeling tear or hole If you did not hear the air suck
12. t 23 A 910 000 r min rpm 14 V Specifications are subject to change without notice and may not apply to every country FG German Model GR Greek Model UK U K Model FR French Model NR Norwegian Model SD Swedish Model Periodic Maintenance Chart GENERAL INFORMATION 1 5 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 FREQUENCY OPERATION Whichever comes first Spark plug clean Spark plug check tODOMETER READING Valve clearance check Air cleaner element clean Air cleaner element replace Throttle grip play check Idle speed check Carburetor synchronization check Fuel system check Engine oil change Oil filter replace Radiator hoses connections check Coolant change Fuel filter replace Fuel hose replace Clutch adjust Drive chain wear check Drive chain lubricate Drive chain slack check Brake lining or pad wear check Brake fluid change Brake fluid level check Brake hose replace Brake master cylinder cup and dust seal replace Caliper piston seal and dust seal replace Brake light switch check Steering check Steering stem bearing lubricate
13. tables list the tightening torque for the major fasteners requiring use of a non permanent locking agent or liquid gasket Letters used in the Remarks column mean L Apply a non permanent locking agent to the threads Apply liquid gasket to the threads Apply an oil to the threads and seating surface LG M Apply molybdenum disulfide grease 5 Tighten the fasteners following the specified sequence SS Apply silicone sealant St Stake the fasteners to prevent loosening Replace the part Fastener GENERAL INFORMATION 1 11 The table below relating tightening torque to thread diameter lists the basic torque for the bolts and nuts Use this table for only the bolts and nuts which do not require a specific torque value All of the values are for use with dry solvent cleaned threads Basic Torque for General Fasteners 100 135 190 25 33 45 54 72 83 115 125 165 165 240 Remarks Fuel System Cooling System Engine Top End Clutch Engine Lubrication System Carburetor Duct Mounting Bolts Coolant Drain Plugs Cylinder Thermostatic Housing Bolt cylinder head Cooling Fan Switch Water Temperature Sensor Water Pump Mounting Bolt Water Pump Pipe Mounting Bolt Radiator Hose Clamp Bolts Radiator Horse Fitting Mounting Bolt cylinder Cooling Fan Mounting Bolt Cylinder Head Cover Bolts Camshaft Chain Guide Bolt Rear Chain Tensioner
14. the motorcycle and store it with the negative lead removed Give a refresh charge every six months during storage 4 Battery life If the battery will not start the engine even after several refresh charges the battery has exceeded it s useful life Replace it Provided however the vehicle s starting system has no problem A WARNING Keep the battery away from sparks and open flames during charging since the battery gives off an explosive gas mixture of hydrogen and oxygen When using a battery charger connect the battery to the charger before turning on the charger This procedure prevents sparks at the battery terminals which could ignite any battery gases No fire should be drawn near the battery or no terminals should have the tightening loosened The electrolyte contains sulfuric acid Be careful not to have it touch your skin or eyes If touched wash it off with liberal amount of water Get medical attention if severe VII Interchangeability with Ordinary Battery A maintenance free battery can fully display its performance only when combined with a proper vehicle electric system Therefore replace a maintenance free battery only on motorcycle which was originally equipped with a maintenance free battery Be careful if a maintenance free battery is installed on a motorcycle which had an ordinary battery as original equipment the maintenance free batterys life will be shortened Torque and Locking Agent The following
15. ther Plate Bolt 98 10 70 L Crankcase Bolts 6 Upper Rear 12 12 85 06 Other 20 20 145 98 27 28 20 5 Crankcase Mating Surfaces A LG Connecting Rod Big End Cap Nuts 25 2 6 19 Wheels Tires Front Axle Clamp Bolts 20 20 145 Front Axle Nut 110 11 0 80 Rear Axle Nut 110 11 0 80 Final Drive Engine Sprocket Cover Bolts L one bolt only Torque Link Nut 25 25 18 0 Torque Link Bolt 25 25 18 0 Engine Sprocket Plate Bolt 8 8 0 9 78 in Ib Rear Sprocket Nuts 74 75 54 Rear Sprocket Studs e L Brakes Bleed Valves 78 0 80 69 in Ib Caliper Mounting Bolts Front 32 33 24 Caliper Assembly Bolts Front 21 24 150 Rear 32 33 24 Pad Spring Screws 29 0 30 26 in Ib Disk Mounting Bolt Front 27 28 20 Rear 23 23 16 5 Brake Hose Banjo Bolts 25 25 GENERAL INFORMATION 1 13 Fastener Torque kg m 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 Suspensions Front Fork Clamp Bolts Upper Lower Front Fork Top Plug Piston Rod Nut Front Fork Bottom Bolts Front Axle Clamp Bolts Rear Shock Absorber Spring Adjuster Locknut Rear Shock Absorber Mounting Nuts Swing Arm Pivot Shaft Nut Rocker Arm Nuts Tie Rod Nuts Steering Steering Stem Head Nut Steering Stem Nut Handlebar Mounting Bolts Handlebar Holder Mounting Bolts Handlebar Holder Clamp Bolt Front
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