Description
This Kawasaki KZ400 KZ Z440 EN450 EN500 Motorcycle Repair Manual 1974-1995 Clymer provides service, maintenance and repair information for KZ400A, S; KZ400B; KZ400C; KZ400G; KZ400H; KZ400A, D; KZ440B; KZ440C; KZ440G; KZ440H; Z440A, C, D; EN450A 454 LTD; EN500A Vulcan 500 motorcycles.
1974, 1975, 1976, 1977, 1978, 1979, 1980, 1981, 1982, 1983, 1984, 1985, 1986, 1987, 1988, 1989, 1990, 1991, 1992, 1993, 1994, 1995
This motorcycle repair manual includes everything you need to know to perform tune-up and routine maintenance on the engine, clutch and transmission, fuel and exhaust, ignition system, steering and suspension, wheels, brakes and tires, frame and body, electrical system and includes wiring diagrams. Features 392 illustrated pages.
QUICK REFERENCE DATA
CHAPTER ONE / GENERAL INFORMATION
Manual organization / Notes, cautions and warnings / Safety first / Service hints / Torque specifications / Fasteners / Lubricants / Parts replacement / Basic hand tools / Test equipment / Mechanic’s tips
CHAPTER TWO / TROUBLESHOOTING
Operating requirements / Troubleshooting instruments / Emergency troubleshooting / Engine starting / Engine performance / Engine noises / Engine lubrication / Clutch / Transmission / Charging system / Starting system / Electrical problems / Ignition system / Breaker point ignition troubleshooting / Breakerless ignition troubleshooting / Excessive vibration / Front suspension and steering / Brake problems / Carburetor troubleshooting
CHAPTER THREE / PERIODIC LUBRICATION, MAINTENANCE AND TUNE-UP
Routine checks / Maintenance intervals / Tires / Battery / Periodic lubrication / Periodic maintenance / Tune-up / Breaker point ignition / Electronic ignition (1980-1983) / Carburetor
CHAPTER FOUR / ENGINE (KZ400 AND KZ440)
Engine / Cylinder head and cylinder head cover (1974-1977 and 1977-1978 Deluxe A models) / Cylinder head and cylinder head cover (1978-1983) / Automatic cam chain tensioner / Valves and valve components / Cylinder / Pistons and piston rings / Oil pump (1974-1977 and 1977-1978 Deluxe A models) / Oil pump (1978-1983) / Oil pressure relief valve (1978-1983) / Alternator and starter / Engine sprocket cover (1978-1983) / Engine sprocket or pulley / Crankcase / Kickstarter (1974-1977 and 1977-1978 Deluxe A models) / Balancer (1974-1977 and 1977-1978 Deluxe A models) / Balancer (1978-1983) / Crankshaft and connecting rods
CHAPTER FIVE / ENGINE (1985-ON)
Servicing engine in frame / Engine / Cylinder head and camshafts / Rocker arm assemblies / Cam chain tensioner / Valves and valve components / Cylinder / Pistons and piston rings / Oil pump / Oil pressure relief valve / Oil level switch / Neutral switch / Alternator, starter drive mechanism and starter / Crankcase / Crankshaft and connecting rods / Balancer shaft
CHAPTER SIX / CLUTCH AND PRIMARY CHAIN
Clutch and primary chain (1974-1983) / Clutch (1985-on)
CHAPTER SEVEN / TRANSMISSION
Shift mechanism (1974-1983) / Shift mechanism (1985-on) / 5-speed transmission (1974-1977 and 1977-1978 Deluxe A models) / 5- and 6-speed transmission (1978-1983, except 1978 Deluxe A) / Transmission (1985-on)
CHAPTER EIGHT / FUEL AND EMISSION CONTROL SYSTEMS
Carburetor / Carburetor adjustment / Emission control (1985-on California models)
CHAPTER NINE / ELECTRICAL SYSTEM
Charging system (1974-1983) / Charging system (1985-on) / Breaker point ignition / Transistorized ignition (1981-1983) / Transistorized ignition (1985-on) / Electric starter / Lighting system / Switches / Horn / Fuses
CHAPTER TEN / COOLING SYSTEM
Cooling system inspection / Radiator and fan / Thermostat / Water pump / Hoses / Thermostatic fan switch and water temperature sensor
CHAPTER ELEVEN / FRONT SUSPENSION AND STEERING
Front wheel / Front hub / Wheel balance / Tire changing / Tire repairs / Steering head / Front fork
CHAPTER TWELVE / REAR SUSPENSION
Rear wheel / Rear hub / Rear wheel coupling / Drive chain / Wheel balancing / Tire changing / Drive belt and pulleys / Rear swing arm / Shock absorbers
CHAPTER THIRTEEN / BRAKES
Front disc brakes / Front brake pad replacement / Front caliper / Master cylinder / Front brake hose replacement / Front brake disc / Drum brakes / Bleeding the system
SUPPLEMENT / EN500 SERVICE INFORMATION
Routine checks / Periodic lubrication / Periodic maintenance / Tune-up / Engine (1990-on) / Clutch and primary chain / Shift mechanism / Fuel and emission control systems / Charging system / Transistorized ignition / Electric starter / Lighting system / Switches / Cooling fan circuit / Junction box and fuses / Cooling system / Front forks / Rear suspension / Master cylinder
INDEX
WIRING DIAGRAMS
