MOTORCYCLE
DATE:
PAGE:
May 10, 2005
1 OF 9
SERVICE INFORMATION
LT-Z400K6
EFFECTIVE ENGINE OR FRAME NO.: JSAAK47A62 100001 –
REFERENCE: E-19, 28, 33
SUBJECT:
APPLICABLE MODEL:
This bulletin is to inform you of the service information for the LT-Z400K6 model.
Please use the following service manual along with the information contained in this bulletin
for proper servicing.
LT-Z400 SERVICE MANUAL (Book): 99500-43062-01E
99500-43060-01F
LT-Z400 SERVICE MANUAL (CD-ROM): 99560-43062-01E
We hope that this information will be useful in your service activities.
CONTENTS
PAGE
SPECIFICATIONS....................................................................................... 2
SERVICE DATA .......................................................................................... 3
NOTE:
Any difference between the LT-Z400K5 (’05-model) and LT-Z400K6 (’06-model) in specifications
and service data are clearly indicated with an asterisk (*).
SPECIFICATIONS
DIMENSIONS AND DRY MASS
Overall length ......................................................................................
Overall width........................................................................................
Overall height ......................................................................................
Wheelbase ..........................................................................................
Front track ...........................................................................................
Rear track............................................................................................
Ground clearance................................................................................
Seat height ..........................................................................................
Dry mass .............................................................................................
1 830 mm (72.0 in)
1 165 mm (45.9 in)
1 160 mm (45.7 in)
1 245 mm (49.0 in)
935 mm (36.8 in)
910 mm (35.8 in)
265 mm (10.4 in)
810 mm (31.9 in)
169 kg (373 lbs)
ENGINE
Type.....................................................................................................
Number of cylinders ............................................................................
Bore.....................................................................................................
Stroke ..................................................................................................
Displacement ......................................................................................
Compression ratio ...............................................................................
Carburetor ...........................................................................................
Air cleaner ...........................................................................................
Starter system .....................................................................................
Lubrication system ..............................................................................
Idle speed............................................................................................
Four-stroke, liquid-cooled,DOHC
1
90.0 mm (3.543 in)
62.6 mm (2.465 in)
398 cm 3 (24.3 cu. in)
11.2 : 1
MIKUNI BSR37 single
Polyurethane foam element
Electric
Dry sump
1 500 ± 100 r/min.
DRIVE TRAIN
Clutch ..................................................................................................
Transmission .......................................................................................
Gearshift pattern, forward ..................................................................
reverse...................................................................
Primary reduction ratio ........................................................................
Gear ratios, Low ................................................................................
2nd ................................................................................
3rd .................................................................................
4th .................................................................................
Top.................................................................................
Reverse .........................................................................
Final reduction ratio.............................................................................
Drive chain ..........................................................................................
Wet multi-plate type
5-forward and 1-reverse
1 down 4 up, foot operated
Foot/hand operated
2.960 (74/25)
2.538 (33/13)
1.666 (30/18)
1.238 (26/21)
1.000 (23/23)
0.846 (22/26)
2.153 (28/13)
2.857 (40/14)
RK 520SMOZ10S, 96 Links
CHASSIS
Front suspension.................................................................................
Rear suspension .................................................................................
Front wheel travel ................................................................................
Rear wheel travel ................................................................................
Caster..................................................................................................
Trail......................................................................................................
Toe-in...................................................................................................
Camber ...............................................................................................
Steering angle .....................................................................................
Turning radius......................................................................................
Front brake ..........................................................................................
Rear brake...........................................................................................
Front tire size.......................................................................................
Rear tire size .......................................................................................
Independent, double wishbone, coil spring, oil damped
Swingarm type, coil spring, oil damped
215 mm (8.5 in)
230 mm (9.1 in)
8.5°
36 mm (1.42 in)
5 mm (0.20 in)
–0.9°
41°
3.1 m (10.2 ft)
Disc brake, twin
Disc brake
AT22 × 7R10 !! tubeless
AT20 × 10R9 !! tubeless
ELECTRICAL
Ignition type.........................................................................................
Ignition timing ......................................................................................
Spark plug ...........................................................................................
Battery.................................................................................................
Generator ............................................................................................
Main fuse.............................................................................................
Fan fuse ..............................................................................................
Headlight .............................................................................................
Brake light/Taillight ..............................................................................
Neutral indicator light...........................................................................
Reverse indicator light.........................................................................
Coolant tempereture warning light ......................................................
Electronic ignition (CDI)
10° B.T.D.C. at 1 500 rpm
NGK CR7E or DENSO U22ESR-N
12 V 28.8 kC (8 Ah)/10 HR
Three-phase A.C. generator
20 A
10 A
12 V 30/30 W × 2
12 V 21/5 W
12 V 3 W
12 V 3 W
12 V 3 W
CAPACITIES
Fuel tank, including reserve .............................................................. 10.0 L (2.6/2.2 US/Imp gal)
reserve .............................................................................
2.7 L (0.7/0.6 US/Imp gal)
Engine oil, oil change......................................................................... 2 000 ml (2.1/1.8 US/Imp qt)
filter change...................................................................... 2 100 ml (2.2/1.8 US/Imp qt)
overhaul............................................................................ 2 200 ml (2.3/1.9 US/Imp qt)
Coolant................................................................................................
1.2 L (1.3/1.1 US/Imp qt)
–2–
SERVICE DATA
VALVE + GUIDE
Unit: mm (in)
ITEM
Valve diam.
STANDARD
36
(1.42)
29
(1.14)
0.10 – 0.20
(0.0039 – 0.0078)
0.20 – 0.30
(0.0078 – 0.0118)
0.010 – 0.037
(0.0004 – 0.0015)
0.030 – 0.057
(0.0012 – 0.0022)
IN.
EX.
Tappet clearance (when cold)
IN.
EX.
Valve guide to valve stem
clearance
IN.
EX.
LIMIT
—
—
—
—
—
—
Valve stem deflection
IN. & EX.
—
0.35
(0.014)
Valve guide I.D.
IN. & EX.
—
Valve stem O.D.
IN.
EX.
5.000 – 5.012
(0.1969 – 0.1973)
4-975 – 4.990
(0.1959 – 0.1965)
4.955 – 4.970
(0.1951 – 0.1957)
Valve stem runout
IN. & EX.
—
Valve head thickness
IN. & EX.
—
0.05
(0.002)
0.5
(0.02)
Valve seat width
IN. & EX.
0.9 – 1.1
(0.035 – 0.043)
—
Valve head radial runout
IN. & EX.
—
Valve spring free length
IN. & EX.
—
0.03
(0.001)
38.8
(1.53)
IN. & EX.
182 – 210 N
(18.6 – 21.4 kgf, 41.0 – 47.2 lbs)
at length 31.5 mm (1.24 in)
Valve spring tension
–3–
—
—
—
CAMSHAFT + CYLINDER HEAD
Unit: mm (in)
ITEM
Cam height
STANDARD
36.320 – 36.370
(1.4299 – 1.4319)
35.200 – 35.250
(1.3858 – 1.3878)
0.019 – 0.053
(0.0007 – 0.0021)
22.012 – 22.025
(0.8666 – 0.8671)
21.972 – 21.993
(0.8653 – 0.8659)
IN.
EX.
Camshaft journal oil clearance
IN. & EX.
Camshaft journal holder I.D.
IN. & EX.
Camshaft journal O.D.
IN. & EX.
Camshaft runout
15th pin
—
Cylinder head cover distortion
—
CYLINDER + PISTON + PISTON RING
ITEM
Compression pressure
(Automatic de-comp. actuated)
Piston to cylinder clearance
Cylinder bore
Piston diam.
Piston ring free end gap
Piston ring end gap
Piston ring to groove clearance
—
1st
R
Approx. 6.9 (0.27)
2nd
R
Approx. 11.5 (0.45)
2nd
0.08 – 0.20
(0.003 – 0.008)
0.08 – 0.20
(0.003 – 0.008)
1st
—
2nd
—
1st
Piston ring groove width
0.78 – 0.80
(0.0307 – 0.0315)
1.30 – 1.32
(0.0512 – 0.0520)
0.81 – 0.83
(0.0319 – 0.0327)
2.01 – 2.03
(0.0791 – 0.0799)
1st
2nd
Oil
–4–
—
Unit: mm (in)
STANDARD
1 000 kPa
(10.0 kgf/cm2, 142 psi)
0.030 – 0.040
(0.0012 – 0.0016)
90.000 – 90.015
(3.5433 – 3.5439)
89.965 – 89.980
(3.5419 – 3.5425)
Measure at 15 mm (0.6 in) from the skirt end.
Cylinder distortion
—
0.10
(0.004)
—
0.05
(0.002)
0.05
(0.002)
—
Cam chain pin (at arrow “3”)
Cylinder head distortion
LIMIT
36.020
(1.4181)
34.900
(1.3740)
0.150
(0.0059)
LIMIT
—
0.120
(0.0047)
Nicks or
Scratches
89.880
(3.5386)
0.05
(0.002)
5.5
(0.22)
9.2
(0.36)
0.50
(0.020)
0.5
(0.020)
0.180
(0.007)
0.150
(0.006)
—
—
—
—
ITEM
Piston ring thickness
1st
2nd
Piston pin bore
Piston pin O.D.
STANDARD
0.71 – 0.76
(0.0280 – 0.0299)
1.08 – 1.10
(0.0425 – 0.0433)
0.77 – 0.79
(0.0303 – 0.0311)
20.002 – 20.008
(0.7875 – 0.7877)
19.995 – 20.000
(0.7872 – 0.7874)
CONROD + CRANKSHAFT
ITEM
Conrod small end I.D.
Conrod big end width
Crank web to web width
—
—
—
20.030
(0.7886)
19.980
(0.7866)
Unit: mm (in)
STANDARD
20.010 – 20.018
(0.7878 – 0.7881)
Conrod deflection
Conrod big end side clearance
LIMIT
—
0.30 – 0.65
(0.012 – 0.026)
21.95 – 22.00
(0.864 – 0.866)
62.0 ± 0.1
(2.441 ± 0.004)
Crankshaft runout
—
Balancer spring free length
—
LIMIT
20.040
(0.7890)
3.0
(0.12)
1.0
(0.04)
—
—
0.08
(0.003)
10.3
(0.41)
OIL PUMP
ITEM
Oil pressure (at 60 °C, 140 °F)
STANDARD
Above 20 kPa (0.2 kgf/cm2, 2.8 psi)
Below 60 kPa (0.6 kgf/cm2, 8.5 psi)
at 3 000 r/min
CLUTCH
ITEM
Clutch cable play
Drive plate thickness
(No. 1 & No. 2)
Drive plate claw width
(No. 1 & No. 2)
Driven plate distortion
LIMIT
—
Unit: mm (in)
STANDARD
10 – 15
(0.4 – 0.6)
2.92 – 3.08
(0.115 – 0.121)
13.7 – 13.8
(0.539 – 0.543)
—
Clutch spring free length
—
–5–
LIMIT
—
2.62
(0.103)
13.2
(0.520)
0.10
(0.004)
49.9
(1.96)
DRIVE TRAIN + DRIVE CHAIN
Unit: mm (in) Except ratio
ITEM
Primary reduction ratio
Final reduction ratio
Gear ratios
Low
2nd
3rd
4th
Top
Reverse
Shift fork to groove clearance
Shift fork groove width
No.1, No.2
& No.3
No.1, No.2
& No.3
Type
Links
20-pitch
length
Shift fork thickness
Drive chain
STANDARD
2.960 (74/25)
2.857 (40/14)
2.538 (33/13)
1.666 (30/18)
1.238 (26/21)
1.000 (23/23)
0.846 (22/26)
2.153 (28/13)
0.1 – 0.3
(0.004 – 0.012)
5.0 – 5.1
(0.197 – 0.201)
4.8 – 4.9
(0.189 – 0.193)
RK520SMOZ10S
96
LIMIT
—
—
—
—
—
—
—
—
0.5
(0.020)
—
—
—
—
319.4
(12.57)
—
Drive chain slack
30 – 40
(1.2 – 1.6)
—
CARBRETOR
SPECIFICATION
ITEM
Carburetor type
Bore size
I.D. No.
Idle r/min
Float height
Main jet
Jet needle
Needle jet
Pilot jet
Pilot screw
Throttle cable play
(M.J.)
(J.N.)
(N.J.)
(P.J.)
(P.S.)
Starter (enricher) cable play
E-19, 28
MIKUNI BSR37
37 mm
* 07G4
1 500 ± 100 r/min
13.0 ± 1.0 mm
(0.51 ± 0.04 in)
#130
5E26-1
P-0M
#22.5
1 and 1/2 turns back
3 – 5 mm
(0.12 – 0.20 in)
0.5 – 1.0 mm
(0.02 – 0.04 in)
–6–
E-33
←
←
* 07G5
←
←
#
←
#
PRE-SET
←
←
THERMOSTAT + RADIATOR + FAN + COOLANT
ITEM
Thermostat valve opening temperature
Thermostat valve lift
Radiator cap valve opening pressure
Engine coolant temp. indicator light
switch operating temperature
Cooling fan thermo-switch operating temperature
Engine coolant type
Engine coolant including reserve
STANDARD/SPECIFICATION
73.5 – 76.5 °C
(164 – 170 °F)
Over 6 mm (0.24 in) at 90 °C (194 °F)
108 – 137 kPa
(1.1 – 1.4 kgf/cm², 15.6 – 19.9 psi)
ON→OFF
Approx. 120 °C (248 °F)
ON→OFF
Approx. 113 °C (235 °F)
ON→OFF
Approx. 88 °C (190 °F)
ON→OFF
Approx. 82 °C (180 °F)
Use an anti-freeze/coolant compatible with aluminum radiator, mixed with distilled water only, at the
ratio of 50:50.
1 200 ml (1.3/1.1 US/lmp qt)
ELECTRICAL
SPECIFICATION
NGK: CR7E
DENSO: U22ESR-N
0.7 – 0.8
(0.028 – 0.031)
Over 8 mm (0.3) at 1 atm.
Type
Gap
Spark performance
Ignition coil resistance
Ignition coil primary peak voltage
TP sensor resistance
Generator coil resistance
Pick-up coil peak voltage
Generator no-load voltage
(When engine is cold)
Generator Max. output
Regulated voltage
Starter relay resistance
Battery
Type designation
Capacity
Fuse size
—
—
—
—
—
—
—
—
—
Unit: mm (in)
ITEM
Spark plug
LIMIT
Primary
0.1 – 1.0 Ω
Secondary
12 – 20 kΩ
Pick-up
Signal
Charging
More than 130 V
3.5 – 6.5 kΩ
350 – 670 Ω
0.09 – 0.50 Ω
0.1 – 1.5 Ω
More than 2.0 V
More than 65 V (AC)
Approx. 150 W at 5 000 r/min
14.0 – 15.5 V at 5 000 r/min
3–6Ω
YTX9-BS
12 V 28.8 kC (8 Ah)/10 HR
20/10 A
–7–
NOTE
Terminal –
Ground
Plug cap –
Terminal
+: B/W, -: B
B – Bl
G – BI
W–B
Br – Br
+: G, -:Bl
WATTAGE
Unit: W
ITEM
Headlight
SPECIFICATION
30 × 2 pcs.
30 × 2 pcs.
21/5
3
3
3
HI
LO
Brake light/Taillight
Reverse indicator light
Neutral indicator light
Engine coolant temp. indicator light
BRAKE + WHEEL
Unit: mm (in)
ITEM
Rear brake pedal height
Brake caliper cylinder bore
Front
Rear
Brake caliper piston diam.
Front
Rear
Brake fluid type
Brake disc thickness
Front
Rear
STANDARD/SPECIFICATION
0 – 10
(0 – 0.4)
32.03 – 32.08
(1.2610 – 1.2630)
33.96 – 34.01
(1.3370 – 1.3390)
31.948 – 31.998
(1.2578 – 1.2598)
33.878 – 33.928
(1.3338 – 1.3357)
DOT 4
2.8 – 3.2
(0.110 – 0.126)
3.8 – 4.2
(0.150 – 0.165)
Brake disc runout (Front & Rear)
Master cylinder bore
—
Front
Rear
Master cylinder piston diam.
Front
Rear
Turning radius
Toe-in (with 75 kg, 165 lbs)
Camber
Caster
Wheel rim size
Tire size
Tire type
Tire tread depth
Wheel axle runout
Front
Rear
Front
Rear
Front
Rear
12.700 – 12.743
(0.5000 – 0.5017)
14.000 – 14.043
(0.5512 – 0.5529)
12.657 – 12.684
(0.4983 – 0.4994)
13.957 – 13.984
(0.5495 – 0.5506)
3.1 m (10.2 ft)
5±4
(0.20 ± 0.16)
–0.9°
8.5°
10 × 5.5 AT
9 × 8.0 AT
AT22 × 7R10 ✩✩
AT20 × 10R9 ✩✩
DUNLOP: KT331
DUNLOP: KT335
Front
—
Rear
—
Rear
—
–8–
LIMIT
—
—
—
—
—
—
2.5
(0.098)
3.5
(0.138)
0.30
(0.012)
—
—
—
—
—
—
—
—
—
—
4.0
(0.16)
4.0
(0.16)
6.0
(0.24)
SUSPENSION
ITEM
Front shock absorber spring
pre-load adjustment
Front suspension damping
force adjuster
Rear shock absorber spring
pre-load adjustment
Rear suspension damping
force adjuster
Unit: mm (in)
STANDARD
LIMIT
287.7 (11.327)
—
Rebound
Compression
1 and 1/2 turns out
1 and 3/4 turns out
—
—
233 (9.173)
Rebound
Compression
—
1 and 1/2 turns out
2 turns out
—
—
TIRE PRESSURE
COLD INFLATION
TIRE PRESSURE
FRONT
REAR
kPa
kgf/cm2
psi
30
27.5
0.30
0.275
4.4
4.0
VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs)
FUEL + OIL
ITEM
Fuel type
Fuel tank capacity including
reserve
reserve
Engine oil type
Engine oil capacity
SPECIFICATION
Use only unleaded gasoline of at least 87 pump
octane (R/2 + M/2) or 91 octane or higher rated by
the research method.
Gasoline containing MTBE (Methyl Tertiary Butyl
Ether), less than 10% ethanol, or less than 5%
methanol with appropriate cosolvents and corrosion inhibitor is permissible.
10.0 L (2.6/2.2 US/lmp qt)
2.7 L (0.7/0.6 US/lmp qt)
* SAE 10W-40, API SF/SG or SH/SJ with JASO MA
Change
2 000 ml (2.1/1.8 US/lmp qt)
Filter change
2 100 ml (2.2/1.8 US/lmp qt)
Overhaul
2 200 ml (2.3/1.9 US/lmp qt)
–9–
NOTE
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