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1 MOTORCYCLE DATE: May 10, 2005 PAGE: 1 OF 9 SUBJECT: SERVICE INFORMATION APPLICABLE MODEL: LT-Z400K6 EFFECTIVE ENGINE OR FRAME NO.: JSAAK47A REFERENCE: E-19, 28, 33 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): E F LT-Z400 SERVICE MANUAL (CD-ROM): E 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 (*).

2 SPECIFICATIONS DIMENSIONS AND DRY MASS Overall length mm (72.0 in) Overall width mm (45.9 in) Overall height mm (45.7 in) Wheelbase mm (49.0 in) track mm (36.8 in) track mm (35.8 in) Ground clearance mm (10.4 in) Seat height mm (31.9 in) Dry mass kg (373 lbs) ENGINE Type... Four-stroke, liquid-cooled,dohc Number of cylinders... 1 Bore mm (3.543 in) Stroke mm (2.465 in) Displacement cm 3 (24.3 cu. in) Compression ratio : 1 Carburetor... MIKUNI BSR37 single Air cleaner... Polyurethane foam element Starter system... Electric Lubrication system... Dry sump Idle speed ± 100 r/min. DRIVE TRAIN Clutch... Wet multi-plate type Transmission... 5-forward and 1-reverse Gearshift pattern, forward... 1 down 4 up, foot operated reverse... Foot/hand operated Primary reduction ratio (74/25) Gear ratios, Low (33/13) 2nd (30/18) 3rd (26/21) 4th (23/23) Top (22/26) Reverse (28/13) Final reduction ratio (40/14) Drive chain... RK 520SMOZ10S, 96 Links CHASSIS suspension... Independent, double wishbone, coil spring, oil damped suspension... Swingarm type, coil spring, oil damped wheel travel mm (8.5 in) wheel travel mm (9.1 in) Caster Trail mm (1.42 in) Toe-in... 5 mm (0.20 in) Camber Steering angle Turning radius m (10.2 ft) brake... Disc brake, twin brake... Disc brake tire size... AT22 7R10!! tubeless tire size... AT20 10R9!! tubeless ELECTRICAL Ignition type... Electronic ignition (CDI) Ignition timing B.T.D.C. at rpm Spark plug... NGK CR7E or DENSO U22ESR-N Battery V 28.8 kc (8 Ah)/10 HR Generator... Three-phase A.C. generator Main fuse A Fan fuse A Headlight V 30/30 W 2 Brake light/taillight V 21/5 W Neutral indicator light V 3 W Reverse indicator light V 3 W Coolant tempereture warning light V 3 W CAPACITIES Fuel tank, including reserve L (2.6/2.2 US/Imp gal) reserve L (0.7/0.6 US/Imp gal) Engine oil, oil change ml (2.1/1.8 US/Imp qt) filter change ml (2.2/1.8 US/Imp qt) overhaul ml (2.3/1.9 US/Imp qt) Coolant L (1.3/1.1 US/Imp qt) 2

3 SERVICE DATA VALVE + GUIDE Valve diam. Tappet clearance (when cold) Valve guide to valve stem clearance Valve stem deflection Valve guide I.D. Valve stem O.D. Valve stem runout Valve head thickness Valve seat width Valve head radial runout Valve spring free length Valve spring tension 36 (1.42) 29 (1.14) ( ) ( ) ( ) ( ) ( ) ( ) ( ) ( ) N ( kgf, lbs) at length 31.5 mm (1.24 in) 0.35 (0.014) 0.05 (0.002) 0.5 (0.02) 0.03 (0.001) 38.8 (1.53) 3

4 CAMSHAFT + CYLINDER HEAD Cam height CYLINDER + PISTON + PISTON RING Camshaft journal oil clearance Camshaft journal holder I.D. Camshaft journal O.D ( ) ( ) ( ) ( ) ( ) (1.4181) (1.3740) (0.0059) Camshaft runout 0.10 (0.004) Cam chain pin (at arrow 3 ) 15th pin Cylinder head distortion Cylinder head cover distortion 0.05 (0.002) 0.05 (0.002) Compression pressure (Automatic de-comp. actuated) kpa (10.0 kgf/cm 2, 142 psi) Piston to cylinder clearance ( ) Cylinder bore ( ) Piston diam ( ) Measure at 15 mm (0.6 in) from the skirt end. Cylinder distortion Piston ring free end gap Piston ring end gap Piston ring to groove clearance Piston ring groove width 1st R Approx. 6.9 (0.27) 2nd R Approx (0.45) 1st 2nd ( ) ( ) 1st 2nd 1st 2nd Oil ( ) ( ) ( ) ( ) (0.0047) Nicks or Scratches (3.5386) 0.05 (0.002) 5.5 (0.22) 9.2 (0.36) 0.50 (0.020) 0.5 (0.020) (0.007) (0.006) 4

5 Piston ring thickness ( ) 1st ( ) 2nd ( ) Piston pin bore ( ) Piston pin O.D ( ) CONROD + CRANKSHAFT OIL PUMP CLUTCH (0.7886) (0.7866) Conrod small end I.D ( ) Conrod deflection Conrod big end side clearance ( ) Conrod big end width ( ) Crank web to web width 62.0 ± 0.1 (2.441 ± 0.004) Crankshaft runout Balancer spring free length (0.7890) 3.0 (0.12) 1.0 (0.04) 0.08 (0.003) 10.3 (0.41) Oil pressure (at 60 C, 140 F) Above 20 kpa (0.2 kgf/cm 2, 2.8 psi) Below 60 kpa (0.6 kgf/cm 2, 8.5 psi) at r/min Clutch cable play ( ) Drive plate thickness (No. 1 & No. 2) Drive plate claw width (No. 1 & No. 2) Driven plate distortion Clutch spring free length ( ) ( ) 2.62 (0.103) 13.2 (0.520) 0.10 (0.004) 49.9 (1.96) 5

6 DRIVE TRAIN + DRIVE CHAIN CARBRETOR Except ratio Primary reduction ratio (74/25) Final reduction ratio (40/14) Gear ratios Low (33/13) 2nd (30/18) 3rd (26/21) 4th (23/23) Top (22/26) Reverse (28/13) Shift fork to groove clearance ( ) Shift fork groove width Shift fork thickness No.1, No.2 & No.3 No.1, No.2 & No ( ) ( ) 0.5 (0.020) Drive chain Type RK520SMOZ10S Links pitch length Drive chain slack ( ) ITEM SPECIFICATION E-19, 28 E-33 Carburetor type MIKUNI BSR37 Bore size 37 mm I.D. No. * 07G4 * 07G5 Idle r/min ± 100 r/min Float height 13.0 ± 1.0 mm (0.51 ± 0.04 in) Main jet (M.J.) #130 # Jet needle (J.N.) 5E26-1 Needle jet (N.J.) P-0M Pilot jet (P.J.) #22.5 # Pilot screw (P.S.) 1 and 1/2 turns back PRE-SET Throttle cable play 3 5 mm ( in) Starter (enricher) cable play mm ( in) (12.57) 6

7 THERMOSTAT + RADIATOR + FAN + COOLANT ELECTRICAL ITEM STANDARD/SPECIFICATION LIMIT Thermostat valve opening temperature C ( F) Thermostat valve lift Over 6 mm (0.24 in) at 90 C (194 F) Radiator cap valve opening pressure Engine coolant temp. indicator light switch operating temperature Cooling fan thermo-switch operating temperature Engine coolant type kpa ( kgf/cm², 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. Engine coolant including reserve ml (1.3/1.1 US/lmp qt) Spark plug Spark performance Ignition coil resistance ITEM SPECIFICATION NOTE Type Gap Primary NGK: CR7E DENSO: U22ESR-N ( ) Over 8 mm (0.3) at 1 atm Ω Terminal Ground Secondary kω Plug cap Terminal Ignition coil primary peak voltage More than 130 V +: B/W, -: B TP sensor resistance kω B Bl Generator coil resistance Pick-up Ω G BI Signal Ω W B Charging Ω Br Br Pick-up coil peak voltage More than 2.0 V +: G, -:Bl Generator no-load voltage (When engine is cold) More than 65 V (AC) Generator Max. output Approx. 150 W at r/min Regulated voltage V at r/min Starter relay resistance 3 6 Ω Battery Type designation YTX9-BS Capacity 12 V 28.8 kc (8 Ah)/10 HR Fuse size 20/10 A 7

8 WATTAGE Unit: W ITEM SPECIFICATION Headlight HI 30 2 pcs. LO 30 2 pcs. Brake light/taillight 21/5 Reverse indicator light 3 Neutral indicator light 3 Engine coolant temp. indicator light 3 BRAKE + WHEEL ITEM STANDARD/SPECIFICATION LIMIT brake pedal height 0 10 (0 0.4) Brake caliper cylinder bore ( ) Brake caliper piston diam ( ) ( ) ( ) Brake fluid type DOT 4 Brake disc thickness Brake disc runout ( & ) Master cylinder bore Master cylinder piston diam ( ) ( ) ( ) ( ) ( ) 2.5 (0.098) 3.5 (0.138) 0.30 (0.012) ( ) Turning radius 3.1 m (10.2 ft) Toe-in (with 75 kg, 165 lbs) 5 ± 4 (0.20 ± 0.16) Camber 0.9 Caster 8.5 Wheel rim size AT AT Tire size AT22 7R10 AT20 10R9 Tire type DUNLOP: KT331 DUNLOP: KT335 Tire tread depth 4.0 (0.16) Wheel axle runout 4.0 (0.16) 6.0 (0.24) 8

9 SUSPENSION TIRE PRESSURE VEHICLE LOAD CAPACITY LIMIT: 110 kg (243 lbs) FUEL + OIL shock absorber spring pre-load adjustment (11.327) suspension damping Rebound 1 and 1/2 turns out force adjuster Compression 1 and 3/4 turns out shock absorber spring pre-load adjustment 233 (9.173) suspension damping Rebound 1 and 1/2 turns out force adjuster Compression 2 turns out COLD INFLATION TIRE PRESSURE kpa kgf/cm 2 psi FRONT REAR ITEM SPECIFICATION NOTE Fuel type 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. Fuel tank capacity including reserve 10.0 L (2.6/2.2 US/lmp qt) reserve 2.7 L (0.7/0.6 US/lmp qt) Engine oil type * SAE 10W-40, API SF/SG or SH/SJ with JASO MA Engine oil capacity Change ml (2.1/1.8 US/lmp qt) Filter change ml (2.2/1.8 US/lmp qt) Overhaul ml (2.3/1.9 US/lmp qt) 9

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