The 1974-1981 Kawasaki Z400, KZ400, Z440, KZ440 repair manual by Haynes covers the following twin-cylinder street bike models:
Book Excerpt: 1974-1981 Kawasaki KZ400/440, Z400/440 Twins Repair Manual
- Kawasaki KZ400 Twin, U.K. and U.S. 1974-1976
- Kawasaki KZ400S, U.S. 1975-1977
- Kawasaki KZ400D, U.S. 1975-1977
- Kawasaki Z400D, U.K. 1976-1979
- Kawasaki KZ400B, U.S. 1978-1979
- Kawasaki Z400B, UK 1978-1980
- Kawasaki KZ400C, U.S. 1978
- Kawasaki KZ400H, U.S. 1979
- Kawasaki Z400, U.K. 1979-1980
- Kawasaki KZ440 Twin, U.K. and U.S. 1980-1981
- Kawasaki KZ440, U.S. 1980-1981
- Kawasaki Z440, U.K. 1981
- Kawasaki KZ440B, U.S. 1980-1981
- Kawasaki Z440C, U.K. 1980-1981
- Kawasaki KZ440D, U.S. 1980-1981
ENGINE, CLUTCH AND TRANSMISSION
ENGINE REASSEMBLY: REPLACING THE TRANSMISSION COMPONENTS AND KICKSTART SHAFT COMPONENTS
FUEL SYSTEM AND LUBRICATION
- Insert the gearchange drum through the large hole in the drive side transmission wall, until it is about half way through. Lightly lubricate the 3rd gear selector fork and slide it onto the change drum so that the locking pin hole faces the crankshaft.
- Ensure that the change drum stopper plate drive pin is in place and position the stopper plate on the end of the change drum. The stopper plate must be fitted with the small projection (which operates the neutral warning switch) facing out, away from the change drum body.
The stopper plate is retained by a circlip on the end of the change drum. The change drum can now be moved across and pushed into the needle bearing in the transmission wall.
- Fit the 3rd gear selector fork locking pin through the fork and into the middle channel in the change drum. Fit a new split pin through the selector fork and pin, and bend back the legs of the pin.
Slide the selector fork rod part way into the transmission and fit the two remaining selector forks. Viewed from the rear of the engine, fit the fork with the cutaway boss to the timing side, with the cutaway facing the timing side transmission wall.
Fit the second fork so that the drive pin is offset towards the drive side wall. Make certain that the fork pins engage correctly with the channels in the change drum.
- Some of the carburetor settings, such as the sizes of the needle jets, main jets and needle positions, etc. are predetermined by the manufacturer.
Under normal circumstances it is unlikely that these settings will require modification, even though there is provision made. If a change appears necessary, it can often be attributed to a developing engine fault.
- As an approximate guide the pilot jet setting controls engine speed up to 1/8 throttle. The throttle slide cutaway controls engine speed from 1/8 to 1/4 throttle and the position of the needle in the slide form 1/4 to 3/4 throttle.
The size of the main jet is responsible for engine speed at the final 3/4 to full throttle. It should be added however that these are only guide lines.
There is no clearly defined demarcation line due to a certain amount of overlap which occurs between the carburetor components involved.
- Always err slightly on the side of a rich mixture, since a weak mixture will cause the engine to overheat. Reference to Chapter 3 will show how the condition of the spark plugs can be interpreted with some experience as a reliable guide to carburetor mixture strength.
Flat spots in the carburetion can usually be traced to a defective timing advancer. If the advancer action is suspect, it can be detected by checking the ignition timing with a stroboscope.
- Unlike a two-stroke, the exhaust system does not require such frequent attention because the exhaust gases are usually or a less oily nature.
- Do not run the machine with the exhaust baffles removed, or with a quite different type of silencer fitted.
The standard production silencers have been designed to give the best possible performance, while subduing the exhaust note to an acceptable level.
Although a modified exhaust system or one without baffles, may give the illusion of greater speed as a result of the changed exhaust note, the chances are that performance will have suffered accordingly.
Subject: 1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981 Kawasaki Z400, KZ400, Z440, KZ440 service, maintenance, repair. ISBN-10: 0856967114 | ISBN-13: 9780856967115 | Haynes 281