ZXR400 Motorcycle Service Manual Supplement
Contents
1. 6 20 mm 8 6 CRANKSHAFT TRANSMISSION Special Tools Socket Wrench Hex 8 57001 1268 Sealant Kawasaki Bond Silicone Sealant 56019 120 Outside Circlip Pliers 57001 144 Kawasaki Bond Liquid Gasket Silver 92104 002 O A Crankcase Crankcase Assembly Note Refer to the base manual noting the following The crankcase bolt seating surfaces on the radiator brackets should be cleaned with a high flash point solvent before bolt tightening This prevent the bolt from getting over tightening on the plate 1 Lower Crankcase 2 Radiator Bracket CRANKSHAFT TRANSMISSION 8 72. CRANKSHAFT TRANSMISSION 8 1 Crankshaft Transmission Table of Contents Exploded View ee Specifications ccccsseeseeseerees Special Tools Osorno Crankcase hai east Crankcase Assembly Note 8 2 CRANKSHAFT TRANSMISSION Exploded View G T1 9 8 N m 1 0 kg m 7 0 ft lb T2 12 N m 1 2 kg m 8 5 ft lb T3 15 N m 1 5 kg m 11 0 ft Ib T4 T5 T6 20 N m 2 0 kg m 14 5 ft Ib 25 N m 2 6 kg m 19 ft lb 27 N m 2 8 kg m 20 ft lb Apply grease HG Apply high temperature grease LG Apply liquid gasket black Kawasaki Bond L SS Apply silicone sealant Kawasaki O 92104 1003 to the mating surface of the right and left crankcase halves Apply a non permanent locking agent to the threads Bond 56019 120 to the gaskets and the threads Apply oil CRANKSHAFT TRANSMISSION 8 3 8 4 CRANKSHAFT TRANSMISSION Specifications Item Standard Service Limit Crankshaft Connecting Rods Connecting rod big end side clearance 0 13 0 38 mm 0 60 mm Connecting rod big end bearing insert crankpin clearance 0 031 0 059 mm 0 10mm Crankpin diameter 29 984 30 000 mm 29 97 mm Marking None 29 984 29 994 mm o 29 995 30 000 mm a Connecting rod big end bore diameter 33 000 33 016 mm Marking None 33 000 33 008 mm o 33 009 33 016 mm Connecting rod big end bearing insert thickness Brown 1 480 1 485 mm Blac
3. k 1 485 1 490 mm Blue 1 490 1 494 mm Connecting rod big end bearing insert selection Con Rod Big End Crankpin Diameter Bearing Insert Bore Diameter Marking Marking Size Color Part Number o None Blue 92028 1492 None None 92028 1493 o o None o 92028 1494 Crankshaft side clearance 0 05 0 20 mm 0 40 mm Crankshaft runout 0 02 mm or less 0 05 mm TIR Crankshaft main bearing insert journal clearance 0 014 0 038 mm 0 08 mm Crankshaft main journal diameter 29 984 30 000 mm 29 96 mm Marking None 29 984 29 992 mm 1 29 993 30 000 mm Crankcase main bearing bore diameter 33 000 33 016 mm Marking o 33 000 33 008 mm None 33 009 33 016 mm Crankshaft main bearing insert thickness Brown 1 491 1 495 mm Black 1 495 1 499 mm Blue 1 499 1 503 mm Item CRANKSHAFT TRANSMISSION 8 5 Standard Service Limit Crankshaft main bearing insert selection Crankcase Main Bearing Bore Diameter Mark Crankshaft Main Journal Diameter Mark Bearing Insert Size Color Part Number Journal Nos 92028 1418 5 Brown 1 2 3 4 lack 92028 1421 92028 1417 5 92028 1420 1 2 3 4 92028 1416 5 The bearing inserts for No 5 has no oil groove Transmission Shift fork ear thickness Gear shift fork groove width Shift fork guide pin diameter Shift drum groove width 4 9 5 0 mm 5 05 5 15 mm 5 9 6 0 mm 6 05
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