Kawasaki

ZXR400R

'89 Racing Kit Manual

fJJftOC

1989.2.16

General Specifications Items Engine

Compression Power Torque Valve Timing Inlet Inlet Duration Exhaust Exhaust Duration Fuel (RON) Ratio

ZXR400R ( ( ( ( F F F F 3 3 3 3 ) ) ) ) 13. 0 7 5 PS/1 3, 5 0 0 rpm 4. 2 kg-m/ 1 0, 0 0 0 rpm

Open Close

280·
Open Close

3 5· 65' 65· 35·

(BTDC) (ABDC) (BTDC) (ABDC)

280·
(98""" 100)

Drive Train
Reduction Ratio Overall Drive Ratio (6th gear)

(F3. SP) (F3. SP)

2.412 2.933 6.564

(41/17)---(44/15) .......7.984

Chassis
Steering Damper Rate ( Turn Angle Front Tyre ( (

F 3, S P ) F 3, S P )
F 3) :
Type : Size

8 ± 3 kg O. 1 5 ml s 2 2 • ( Standard 3 0
Racing Slick

125/595-17

Rear Tyre

F3)

: Type : Size

Brake Fluid

Ignition
Spark Plug

(F __

~-=-!_~ __ )

--t-~-~-~-~-~~_-~-_---__-_---- --1 6 0/ 6 1 5 R17 NGK R0045-10

(F3)

General Specifications Item Carburetor Specifications ( F 3,

Idle Speed Main Jet Jet Needle Mark Needle Height Needle Washers Pilot Screw Optional Main Jets

ZXR400R SP) 1. 5 0 0 ---- . 2 #165 #140 N70A(SP

Position 3

[13

0 0 0 rpm N78B)

SP

4>0.7X2><4 1/2 .---1 F3 SP 1 5 5,. 1 6 0, 1 6 5 , 170,175,180 #132,135,138,140, 142.145.148 #150 (SP#90, 110) #38 31.
(F 3 )
Inlet Exhaust

# 1 5 0,

Main Air Jet Pilot Jet

Camshaft
Camshaft Lobe Height

(F3 )

803----31. 2 0 ...__ . O 2 5 mm

983mm

Valves
Valve Clearance

O.

Piston to Head Gasket Clearance Piston to Valve Clearance Inlet Exhaust Camshaft Lift Centre : Inlet Exhaust

O. O.

6--"'0.
6 nun

min

1. 1 mm
105±1. 105±1.

(ATDC (BTDC 5° ATDC 5° BTDC

12° 12°

Cylinder, Piston
Piston Diameter

(F3)

S.T.D.

Ignition
Spark Plugs

(F3)
Optional ( [I

NGK 3, SP) NGK NGK 15200

R0045-10 R0045-9 R0045-11 rpm (S.T.D.14800

rpm)

IC Igniter

(F 3)

Increased Rev Limit

Power Output

(F3 )

80,-------------------------------------------------------~

/ /

70 ZXR400R ~
, .:
/ /

,
/

/ /

,//~

,
/

60

1l.5 q, 0 3. 5

I O'l

Q)

::::J ({)

C" I-

... 0

0...

3. 0 50

110

30

10

11

12

13

111

Engine Speed ( x 1 0 0 0 RPM)

ZXR400R Wiring Diagram

(F 3,

SP)

!~
~~18f)(

m1----------A/)j8--[)::}---:-A/)j8

~ .. '"

.. ~
e,

c. E

L..- __

!:l/A-------+l-I-=

~---

A!)(8-------f+\J

r----!:l H---A/>l8------<
ot ... N

cr

__lfc~:

A~)I8 )(8 -++--+-----4 A/)I8-44-~--_+~ !:l

~--H-+--.....I

>19 I ':J -l-++---t-1

0=:'-=dJ:-~~
c

-g £~~~~~e£~~~ u 0
tn

~ti!l)~~>-e~.:.:"'C!~

~r-~-+~4-~+-+-~-+~
a)alCOQQ..J°a..cr;r>
Mt....JQ:

>-

-uo

--ro

Cylinder Head ( F 3 )
• • • Remove sharp edges at points marked A. Use a flapper wheel and start with 120 grade aluminium oxide paper. Finish with 200 and then 300 grade paper. Take care not to damage the valve seats. The optional profile will give more power at full throttle but will cause poor running at part throttle.

A:

Remove Sharp Edges

Optional Profile

[Cieaf"ance

O. 6 --...

6. 7

mm ]

• Ensure cylinder head to piston clearance is within limits. If necessary replace standard base gasket (0.2 mm) with kit gasket (0.1 mm) .

• Ensure cylinder head is flat to within

0 _05 mm

9 Barrels ( F 3 )
• Use the kit head gasket (PN: 11004 -1202) Profile the bores as shown in the diagram, this will improve gas flow and give an increase of O. 5 ---- 1. ps

E E
LD

1mm
I

l
N

/1

If=::T~
I

Top Ring Limit

lL::===t==:=:J Camshafts ( F 3 )

1:::::

• Slot the camshaft journals to improve lubrication

Slot

1.

EX

10
• Set clearances to allow for expansion due to heat at racing speeds.

v_a_~veClearance
-

Inlet: Exhaust __

=-__.9_:_ 2 5 ~..9_:.. 2_§

~2()"'__

6-. -2 5 mm

mm_

--1
_

• Set camshaft timing by slackening retaining bolt and rotating camshaft.

Retaining Bolt

Alignment Dowel ----_./

11

• Adjust camshaft so the valve to piston clearance is as in the table.

-----------_- l-- --- -- _------------ -_ ---_.-.

- _-_._Inlet Exhaust

_--

-- ~---

Valve to Piston Clearance

-- - --------- -_ ---_-_

--. _-

o. --- -

-----_

----

--

6 mm -- - --1..-- 1 IBID --_ 12·

---.-

.-

• The Inlet measurement

is made at

ATDC and the Exhaust measurement at

12· BTDC

Pistons (

3)
ratio from

• Use of the kit pistons will increase the compression

12 _ 1

to

1 3 _0

3 Rings

Utilised

Rings Utilised

• Remove No 2 compression

ring to reduce friction.

• Increased oil consumption

whilst using only one compression

ring is normal.

12
Connecting Rods ( F 3 )

• Grind away casting boss from the small ends of the connecting • Ensure each small end weighs within

rods .

± 2g

of each other.

o
• Smooth the beam of the connecting rod with 120 grade aluminium oxide paper.

Smooth

Smooth

• Ensure that the total weight of the connecting • Polish connecting

rods are within

± 2g

of each other.

rod beams with 200 and then 300 grade aluminium rod bolts to

oxide paper.

• Tighten connecting

2-4

---- 2 _8 kg-- m

13

Transmission
The standard transmission of the

Z X R 4 0 0 R (Z X 4 0 0 J ) is

retained

Optional

3,

SP)
(P N : 92150 1206)
o-ring

Removal of Generator and Starter Motor • Replace generator and starter gear with bolt and washer

(PN : 670B 1505)

(PN: 92022

1820) 13>0) o-ring (PN: 92055-1262) 125)

• Replace starter motor with plug bolt

(PN: 920(,(; (PN: 130C061U)andwashedPN:92022

• Plug wiring hole in generator cover with

(P N : 92071

1172)

Crankshaft

Engine Casing

Washer O-ring Bolt

C)~

Bolt

&~

~
Generator Cover

Plug

14

Remove

15 Exhaust (F 3, SP)

• Remove standard exhaust and replace with kit parts.

Collar: 18069-109f

Spacer:

18069-W93
Bolt:

92150-1207

Flange: 18069-1084

Gasket: 18067-004

16

Grommet

(PN:92160-1012) (PN:92002-1445)
( Bolt

Washer

(PN:92022-092)
Nut

(PN:92015-1432)

17 Cooling ( F 3, S P)

• Remove standard hose and fit: Hose: Hose:

(PN:39062-1355) (PN:39062-1356)

• Apply tape to radiator to maintain temperature of

7 O·C

Tape

• Mount kit radiator with kit fixings.

Grommcl(PN:92075-1901)
~ ~BOIt Ferrule (PN' (PN' 92027-1062: 13080625)

18
• Use of the kit radiator will necessitate the repositioning of the thermostat cover.

:; I) J /j '"

'!} ~

Standard Orientation

Kit Orientation

19

Oil Cooler ( r 3 )

Use oil filter bolt kit part ( PN:

(J2150

1205)

although this part will need adapting

0';9;"31 Holes

"-Solid
Modify oil filter bolt by drilling a 7mm hole in the end

20
• Weld brackets and secure oil

(PN: 92160-1169) to underside of cooler with strap (PN: 92072-1176)

radiator,

Radiator Location

D--

Bracket ( PN: 92160

-116 9)

---n

Strap(PN:92072-1176)

~l

0 <D

o
OJ

0 <D

1\
30

In
30

~
30

Bracket (PN:92160-11691

Dimensions

21
• Install the oil cooler using unions and fittings and hoses (PN:

(PN: 92005- 1177,92005-1178.92005

--1202)

92059- 1969)

FRONT

<,
:-Union ( 4 5 . ) (PN:92005-1178)

Union

(PN:92005-1177)

Hose

(PN:92059-1969)
Sump

Union ( 45')

(PN. 92005-1178

)----s:::, "'~----

/~~g
Union
/
,

92 005 - 11 7 s

~~ N • 92005

- 120 2 )

0'

22 Oil Cooler ( S P )
• Reposition the oil cooler as shown below.

Oil Cooler

-<~

Cable Tie Hoses

Cut Here

23
Airbox (

r~

r: )

Crankcase Breather Hose

Remove standard airbox assembly and replace with kit airtray ( [' N : 4 91 ~5 - ] (57)

• Secure airtray using four clamps

(P N : 13183 - 1490)

24

Ignition Lead Holes

Ignition Coils

Bellmouth

25 Carburettors ( F 3,
• Settings (

SP)

F3)

Main Jet Needle Needle Washers Pilot Screw Idle Speed

# 16 5

(Option

.p O. 7
1

N 7 0 A,

# 17 5)
2 4
rpm

112 ....... 1

(Slot 3) X Turns Out

>:

5 0 0 ----- 0 0 2. 0

• Settings

SP)

Main Jet Needle Pilot Screw Idle Speed

1 .:J 0 (Option # 1 4 8 ) N 78 D, 1/ 2"'- 1 Turns Out

1.

5 0 0"' 2.

0 0 0 rpm

• Attatch intake trumpets

(PN: 14073

1399

fi3,14073

]·W5 SP)

using bolts

(PN: 130P,0512)

• Run the engine in keeping to the maximum speeds as outlined below.

j, '"' 4. 5. 6. 7

000 000 000 000 000

rpm rpm rpm rpm rpm

->

() 0 km 3 0 kn 3 () km 3 0 km 30km 1 --... 2 p s .
more than one that is not.

• An engine that is correctly run in will produce

26

Intake Trumpet ( F 3,

SP)

......

-.--._ .-- - . _ .. __ ... __ .... _.....

Speed Std Low

. - -._-----

Engine Std Std

Intak~ Tru,:"pet

SP

__

•• __

0'

._

•..

F3

Std Low

••

_•••••

•••

__

•••

3
Std Std

Kit

I
High

F3

Kit

S P Kit F 3 .,_'_.'- .. - .--Kit --.--"_'r 3 Kit r 3 Kit S P Kit S P Kit._. -

L= 3 L = ..5 ---.- _. ( L= 5 ( L=5 ( L=3 ( .- = 3 L __ ._.

( (
,

...

_-_

0) 0 ). 0) 0) 0) 0) -_._-.

'1

27

\
1

7
I (

I
Ignition
• Sparkplugs

(F 3)

NGK NGK

0 c1:=, R 0 1 6-- I)

I) ( Option ( Option

),

10 (
10 (

Standard)

),

Standard

i.

1 1 ( Option 1 1 ( Option )

rc Igniter

(F

3) 6
v

• The kit rotor increases the static advance by

over standard.

• The kit IC igniter increases the maximum engine speed from

14, SOU rpm

to

15.200

rpm

Ignition Curve
60

F 3 Kit

50
40 30 20 10 00

VI'"
I --- -1

-_

//
1

---

/1

__~l ___ J C\
ZXR400R

(deg I

I
3
<1

I
8 9 10

I
I
11 12 13

14

15

RPM

(x1000rpm)

29
• Cable Routing
Clamp
(92170-1129)

Fuel Pump Relay Temperature Sender ~iter

~ulator

Rectifier

Starter Motor Lead Clamp

Starter Switch Lead

(92037-199,1)

Battery (+) Lead Starter Motor Lead Starter Relay

Engine Stop Run Coil Leads Inside Frame Cable Tie

To Ignition Coils

Clamp(92170-1129)

Run Harness Through

Bracket

30

Gearing ( F 3,
• Front Sprocket Rear Sprocket

SP) 1 5 T ( Kit) . 1 6 T ( Std ) , 1 7 T 4 1 T, 4 2 T. 4 3 1'. 4 4 T

(Kit

Optional Final Drive Ratios Fro nt

_____ . .. .

_._

Rear _______________
- .-_2-:-::-::-'"

._._._.

411' 733 563 4 12

I--

421' 2.
?

15T (
---_ .. ..... - -_ .._
,

Kit)

2.
- ..
.......I.

800
6')

431' i ·l ,1 T j !" I ..., g (j '7

I

I
i

1 6 T ( Std)
'--"--

--_ ...
)

2. 2.

L-.

17T

-:-"

~.

r:; I :2.

(~~8 S

(Kit

2.47112.

...J...-.

r:;29 .....J........i:> •__

7 '50 r:;S8 _

• Overall Reduction

6 Th

Gear)

-_
(Kit) -_ .. - -_ (Std)
..

Rear

-.---------:----4 ]T 4 2T
7. 7. 621 14 5 7. 7.

..--.-- ...-I
-1 T
'7. .:) 8 .;

Front

-I 3 TJ

15T

_ ..... __ ...

_"

..

7. 6.

439 974

i3 0:2 .

1 6 l'

L;'__ ( _K_it_) __ ~i_T __

~6_._5_6_4_,--6_.~_I_:.._)_'1. _

_l~.

:3 1 5 8g

I ~_l_~_tL~~
I
i . ,1 g ~.;

s_

• When utilising the optional ratios a different chain may be required.

• Ensure vertical chain slack at mid way between sprockets is between

2 ()--~)UlTn S

31 Steering Damper ( f7 3,
• Fit fork clamp (PN : • Fit steering damper

SP)
hand fork . to frame.

13091 -1 ()28) to left (PN : HOrn J CJ03)

Fork Clamp:

13091-1628

Steering Damper:

44003-1903

• Use clamp

(I' N:

I)

(If)

1 I ') 7~)

to attatch damper to fork clamp.

\i
Clamp: 13091-1573 ~

i'.~ ~~
I

"'-J

Clamp Position

Adjuster

• The damper has 12 settings available, the normal position is 8, +/-1.

32 Steering
• Fit lockstops to reduce steering angle to 22 degrees

(173,

SP)

Lockstops

Wheels
[ Wheels

( I,))

• Standard wheel sizes are used

J
3. 4.

Front Rear

r:;
S

MT MT
0

• rn~ a;lf C: U: L, 1
Front Wheel ( Ii

'/:>' '1 -v (.: :x ~ i- ~

j, ~: P

• Replace speedo mechanism with PN:92143 13391

~:-..-.. ,.:~ . .. .
. ..

'. . . . . . . ~

. .

16'

k~:<:·
.,
'

.... . D .. . ...

...... . ·······················1· .: .':-:-:-:':-:-:-:-:-:-: . .

..
..................... . . ~ . . . ......... . .. . .

/::::::: .

•••••i

... ...

:h

..

Remove

m·········~··ili8···
.: -:.:-:.:-: -:.: ~~:-:

33 Front Brakes ( F 3 )
• Replace front brake pads with

PN : ·13 0 ~0 1182

Front Suspension ( F 3 )
• The standard front suspension is retained.

Rear Suspension ( F 3 j
• Replace rear shock absorber spring with Spring Rate : Kit Std

PN : 921 ,14 14") 3

kg/rum

7.

75

8 kg/mm

34

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KAWASAKI HEAVY INDUSTRIES, LTD.

Consumer Products & Heavy Machinery Group

Part No. 99929-1048-01