ZXR400 Motorcycle Service Manual Supplement
Contents
1. Valves Valve clearance inlet 0 12 0 17 mm ee Exhaust 0 16 0 21 mm sees Valve spring free length 38 2 mm 36 4 mm Valve head thickness Inlet 0 5mm 0 25 mm Exhaust 0 7 mm 0 35 mm Valve stem bend 0 02 mm TIR or under 0 05 mm TIR Valve seat cutting angle 45 32 60 Valve seating surface Width Inlet 0 5 1 0mm gt Exhaust 0 5 1 0 mm Outside diameter Inlet 21 5 21 7 mm gt Exhaust 18 5 18 7 mm me Valve valve guide clearance wobble method Inlet 0 031 0 140 mm 0 34 mm Exhaust 0 085 0 180 mm 0 41 mm Camshaft Height Measurement Camshaft Journal Diameter m A SEI Item Standard ENGINE TOP END 4 5 Service Limit Valve stem diameter Valve guide inside diameter 3 975 3 990 mm 3 955 3 970 mm 4 000 4 012 mm 3 96 mm 3 94 mm 4 08 mm Cylinder Piston Cylinder inside diameter Piston diameter Piston cylinder clearance Oversize piston and rings Piston ring groove clearance Piston ring end gap 57 000 57 012 mm 56 942 56 957 mm 0 043 0 070 mm 0 5 mm 0 030 0 070 mm 0 15 0 30 mm 0 35 0 50 mm 57 10 mm 56 79 mm 0 17 mm 0 6 mm 0 8 mm v ai LL Valve Head Valve Stem Bend m Valve stem diameter Valve head thickness Camshaft Runout 4 6 ENGINE TOP END Special Tools Compression Gauge 57001 221 Valve Spring Compr2. ENGINE TOP END 4 1 Engine Top End Table of Contents 4 l Exploded View RA AE gr ara 4 2 Specifications ta SCH on Special Tools Sealant 4 2 ENGINE TOP END Exploded View L1 L2 Models and L1 L3 Models than U K Model other go EK 0 UK U K and L4 L5 Models A 6mm B C 8mm ENGINE TOP END 4 3 Sg L3 L5 Models L1 L2 Models 4 9 N m 0 5 kg m 43 in Ib 5 9 N m 0 6 kg m 52 in Ib 8 8 N m 0 9 kg m 78 in Ib 9 8 N m 1 0 kg m 7 0 ft lb 12 N m 1 2 kg m 8 5 ft lb 25 N m 2 5 kg m 18 ft ib 27 N m 2 8 kg m 20 ft lb dad dni r Apply a non permanent locking agent to the threads Apply molybdenum disulfide grease Apply silicone sealant to the threads O Apply oil 4 4 ENGINE TOP END Specifications Standard Service Limit Camshaft Cam height Inlet 31 778 31 918 mm 31 68 mm Exhaust 31 469 31 609 mm 31 37 mm Camshaft camshaft cap clearance A 0 028 0 071 mm 0 16 mm B 0 078 0 121 mm 0 21 mm Camshaft journal diameter A 23 950 23 972 mm 23 92 mm B 23 900 23 922 mm 23 87 mm Camshaft bearing inside diameter 24 000 24 021 mm 24 08 mm Camshaft runout 0 1 mm TIR Camshaft chain 20 link length 127 0 127 4 mm 128 9 mm Cylinder Head Cylinder compression Usable range 686 1 079 kPa 7 0 11 0 kg cm 99 156 psi 330 r min rpm Cylinder head warp
3. essor Joint 57001 1271 B Compression Gauge Adapter M10 X 1 0 57001 1317 Valve Guide Arbor 04 57001 S D Rocker Arm Holder 57001 1270 Valve Guide Reamer 4 57001 1274 fen Valve Spring Compressor Assembly 57001 241 Valve Seat Cutter Holder 04 57001 1275 Shc Valve Spring Compressor Adapter 921 57001 1 Valve Seat Cutter 45 920 5 57001 1307 Valve Seat Cutter 30 18 57001 1308 e Valve Seat Cutter Holder Bar 57001 1128 ENGINE TOP END 4 7 Valve Seat Cutter 65 919 57001 1310 age Valve Seat Cutter 60 925 57001 1328 Piston Base 08 57001 147 Piston Pin Puller Assembly 57001 910 Valve Seat Cutter 45 22 57001 1205 Valve Seat Cutter 32 22 57001 1206 eee e a oc Sealant Kawasaki Bond Silicone Sealant 56019 120 a v ei
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