2003-2006 Kawasaki KFX400 ATV Repair Manual

Kawasaki KFX400 All Terrain Vehicle Service Manual

KFX400 All Terrain Vehicle Service Manual Supplement

Foreword This Kawasaki Service manual supplement information provides unique to the Kawasaki KSF400-A1, which is based on the Suzuki LT-Z400K3. It must be used in conjunction with the other chapters of this manual. Read both this supplement and the base manual for complete information on proper service procedures for the model covered by this manual. This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used. For the duration of the warranty period, we recommend that all repairs and scheduled maintenance be performed in accordance with this service manual. Any owner maintenance or repair procedure not performed in accordance with this manual may void the warranty. To get the longest life out of your vehicle:  Follow the Periodic Maintenance Chart in the Service Manual.  Be alert for problems and non-scheduled maintenance.  Use proper tools and genuine Kawasaki Vehicle parts. Special tools, gauges, and testers that are necessary when servicing Kawasaki vehicles listed in this manual. Genuine parts provided as spare parts are listed in the Parts Catalog.  Follow the procedures in this manual carefully. Don’t take shortcuts.  Remember to keep complete records of maintenance and repair with dates and any new parts installed. How to Use This Manual In preparing this manual, the product was divided into its major systems, and these systems became the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Group Index shows you all of the product’s systems and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. For example, if you want crankshaft information, use the Group Index to locate the Engine chapter. Then, use the Table of Contents on the first page of the chapter to find the Crankshaft section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. WARNING This warning symbol identified special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment. This manual contains the other symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE  This note symbol indicates points of particular interest for more efficient and convenient operation.  Indicates a procedural step or work to be done.

Symbol Throughout this manual are symbols indicating instructions and other information necessary for servicing. The meaning of each symbol is included in the table below. Where applicable, comparable Kawasaki products and their part numbers have been included. SYMBOL SUZUKI DEFINITION KAWASAKI DEFINITION Torque control required. Data beside it indicates specified torque. ← Indicates service data. ← Apply oil. Use engine oil unless otherwise specified. ← Apply molybdenum oil solution. (mixture of engine oil and SUZUKI MOLY PASTE in a ratio of 1 : 1) Apply molybdenum disulfide oil. (a mixture of engine oil and molybdenum disulfide grease with a weight ratio of 1:1) Apply SUZUKI SUPER GREASE “A”. 99000-25030 (For USA) 99000-25010 (For the other countries) Apply grease. Apply SUZUKI SILICONE GRESE. 99000-25100 Apply Silicone grease. Apply SUZUKI MOLY PASTE. 99000-25140 Apply molybdenum disulfide grease. Apply SUZUKI BOND “1207B”. 99104-31140 (For USA) 99000-31140 (For the other countries) Apply THREE BOND “TB1207B”. Apply SUZUKI BOND “1215”. 99000-31110 Apply THREE BOND “TB1215”. Apply THREAD LOCK SUPER “1303”. 99000-32030 Apply a non-permanent locking agent. Apply THREAD LOCK SUPER “1322”. 99000-32110 (Except USA) Apply a non-permanent locking agent. Apply THREAD LOCK “1342”. 99000-32050 Apply a non-permanent locking agent.

SYMBOL SUZUKI DEFINITION KAWASAKI DEFINITION Apply THREAD LOCK SUPER “1360”. 99000-32130 Apply a non-permanent locking agent. Apply or use brake fluid, ← Measure in voltage range. ← Measure in resistance range. ← Measure in current range. ← Measure in diode test range. Use a suitable commercially available digital multi meter for a diode tester and measure in diode test range. Measure in continuity test range. ← Use special tool. Refer to the special tools in Servicing Information chapter. Use engine coolant. 99000-99032-11 (Except USA) Permanent type of antifreeze (soft water and ethylene glycol plus corrosion and rust inhibitor chemicals for aluminum engines and radiators)

GENERAL INFORMATION 1-1 General Information Contents WARNING/CAUTION/NOTE ....................................................................................... Base Manual GENERAL PRECAUTIONS ........................................................................................ 1-2 KAWASAKI KSF400-A1 .............................................................................................. 1-3 SERIAL NUMBER LOCATION .................................................................................... Base Manual FUEL AND OIL RECOMMENDATION ......................................................................... Base Manual FUEL ....................................................................................................................... Base Manual ENGINE OIL ............................................................................................................ Base Manual BRAKE FLUID ......................................................................................................... Base Manual ENGINE COOLANT................................................................................................. Base Manual BREAK-IN PROCEDURES ......................................................................................... Base Manual INFORMATION LABELS ............................................................................................. Base Manual SPECIFICATIONS....................................................................................................... 1-4 COUNTRY AND AREA CODES .................................................................................. 1-6

GENERAL INFORMATION 1-2 GENERAL PRECAUTIONS CAUTION  If parts replacement is necessary, replace the parts with KAWASAKI Genuine Parts or their equivalent.  When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.  Be sure to use special tools when instructed.  Make sure that all parts used in reassembly are clean. Lubricate them when specified.  Use the specified lubricants, bands, or sealant.  When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable, and replace the terminal cover on the positive terminal.  When performing service to electrical parts, if the service procedures not require use of battery power, disconnect the negative cable the battery.  When tightening the cylinder head and case bolts and nuts tighten the larger sizes first. Always tighten the bolts and nuts from the inside working out, in a crisscross manner.  Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, self-locking nuts, cotter pins, circlips, and certain other parts as specified, be sure to replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.  Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.  Use a torque wrench to tighten fasteners to the specified torque. Wipe off grease and oil if a thread is smeared with them.  After reassembling, check parts for tightness and proper operation.  To protect the environment, do not unlawfully dispose of used motor oil and all other fluids: batteries and tires.  To protect the Earth’s natural resources, properly dispose of used motorcycle and parts.

2003-2006 Kawasaki KFX400 ATV Repair Manual

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