Kawasaki · Kawasaki Z1 / KZ air-cooled DOHC four (1972-1985)

KZ400 / KZ440 twin

Library entry covers 1974-1983

30 factory 42 guideline

Published source

Kawasaki KZ400 Shop Manual 1974-77, 5th revision Aug 1978

Factory workshop manual. Covers 1974-1977 (KZ400D, KZ400S).

Open the source

72 items for a 1979 model, grouped by interval the way a factory chart is laid out.

How this bike is built (what the schedule is based on)

Engine cycle: Four-stroke
Engine lubrication: Wet sump (oil in crankcase)
Oil filtration: Replaceable cartridge or spin-on filter
Valve gear: Overhead cam, screw/locknut adjusters
Ignition: Battery and coil with contact points
Charging: Alternator / stator with rectifier
Battery: Wet cell (flooded lead-acid, needs topping up)
Fuel system: Two or more carburetors
Cooling: Air / oil cooled
Primary drive: Gear or chain inside engine, shares engine oil
Gearbox oil: Shares engine oil
Clutch control: Hand lever, cable
Final drive: Chain
Front suspension: Telescopic fork
Rear suspension: Swingarm, twin shocks
Front brake: Disc, hydraulic
Rear brake: Drum (or band / belt rim)
Wheels: Spoked, tubed
Sidecar: No sidecar

Maintenance schedule

1979 Kawasaki KZ400 / KZ440 twin

On the road: every 186 mi

1 item

Lubricate drive chain

Pre-ride / on the road

Factory

Factory: Chart p.180: every 300 km

On the road: every 200 mi

1 item

Check engine oil level

Pre-ride / on the road

Guideline

Each fuel stop on old machines. Dry sump: check the tank hot, engine idling or just stopped, per your manual.

On the road: every 300 mi

2 items

Check lights, horn, brake light switches

Pre-ride / on the road

Guideline
Check tire pressures

Pre-ride / on the road

Guideline

On the road: every 497 mi

1 item

Check chain slack and rear wheel alignment

Pre-ride / on the road

Factory

Manual: Check, adjust drive chain. Factory: Chart p.180: every 800 km

On the road: every 1,000 mi

1 item

Check road kit: plugs, points file, master link, tube patches, wire, tape

Pre-ride / on the road

Guideline

On the road: every 6,214 mi

1 item

Walk-around: check nuts and bolts for vibration loosening

Pre-ride / on the road

Factory

Manual: Tighten bolts and nuts. Factory: Chart p.180: initial 800 km, then every 10,000 km

Every 1,000 mi or 1 month

1 item

Check battery electrolyte, top up with distilled water

Ignition and electrics

Guideline

Wet-cell batteries on old machines need regular topping up, more in hot weather.

Every 1,500 mi or 6 months

1 item

Clean drive chain thoroughly (remove and soak, re-lube)

Final drive

Guideline

Non O-ring chains on old machines: remove, clean, soak in hot chain grease or lube, refit with the master link clip closed end leading.

Every 1,864 mi

1 item

Change engine oil

Engine

Factory

Factory: Chart p.180: initial 800 km, then every 3,000 km

Every 2,000 mi or 12 months

2 items

Grease swingarm pivot

Rear suspension and frame

Guideline
Lubricate control cables and lever pivots

Controls and cables

Guideline

Every 3,000 mi or 12 months

11 items

Adjust cam chain tensioner (manual-adjust models)

Engine

Guideline
Check engine mounting bolts and plates

Engine

Guideline
Check / set ignition timing

Ignition and electrics

Guideline
Adjust clutch pushrod / clutch adjuster

Primary and gearbox

Guideline
Check chain guard, chain oiler (if fitted), rear chain case

Final drive

Guideline
Inspect chain and sprockets for wear (measure stretch)

Final drive

Guideline
Check steering damper (friction or hydraulic)

Front end

Guideline
Inspect fork seals, stanchions and fork boots

Front end

Guideline
Check footrests, pegs, rear brake and gear lever pivots

Rear suspension and frame

Guideline
Grease and check center / side stand and springs

Rear suspension and frame

Guideline
Check wheel bearings for play

Wheels and tires

Guideline

Every 3,107 mi

15 items

Check and adjust valve clearances

Engine

Factory

Manual: Check valve clearance. Factory: Chart p.180: initial 800 km, then every 5,000 km
Inspect, clean and gap spark plugs

Engine

Factory

Manual: Clean, set spark plug gaps. Factory: Chart p.180: initial 800 and 5,000 km, then every 5,000 km
Perform general lubrication

Engine

Factory

Factory: Chart p.180: initial 5,000 km, then every 5,000 km
Check throttle cable(s) free play and return

Fuel and air

Factory

Manual: Check, adjust throttle cables. Factory: Chart p.180: initial 800 and 5,000 km, then every 5,000 km
Clean / inspect air filter

Fuel and air

Factory

Manual: Clean air cleaner element. Factory: Chart p.180: initial 5,000 km, then every 5,000 km
Clean fuel tap filter / sediment bowl

Fuel and air

Factory

Manual: Clean fuel system. Factory: Chart p.180: initial 800 and 5,000 km, then every 5,000 km
Synchronize carburetors

Fuel and air

Factory

Manual: Check, adjust carburetors. Factory: Chart p.180: initial 800 and 5,000 km, then every 5,000 km
Clean and gap contact breaker points, oil cam felt

Ignition and electrics

Factory

Manual: Check, adjust points, timing. Factory: Chart p.180: initial 800 km, then every 5,000 km
Adjust clutch free play, lubricate cable and lever pivot

Primary and gearbox

Factory

Manual: Check, adjust clutch. Factory: Chart p.180: initial 800 and 5,000 km, then every 5,000 km
Adjust camshaft chain

Final drive

Factory

Factory: Chart p.180: initial 800 km, then every 5,000 km
Replace chain and sprockets (wear based)

Final drive

Factory

Manual: Check drive chain wear. Factory: Chart p.180: initial 5,000 km, then every 5,000 km
Adjust rear drum brake and rod / cable linkage

Brakes

Factory

Manual: Check, adjust brakes. Factory: Chart p.180: initial 800 and 5,000 km, then every 5,000 km
Check brake fluid level

Brakes

Factory

Factory: Chart p.180: initial 800 and 5,000 km, then every 5,000 km
Check spoke tension and wheel true

Wheels and tires

Factory

Manual: Check spoke tightness and rim runout. Factory: Chart p.180: initial 800 and 5,000 km, then every 5,000 km
Inspect tire tread, sidewalls and date codes

Wheels and tires

Factory

Manual: Check tire pressure and tread wear. Factory: Chart p.180: initial 800 and 5,000 km, then every 5,000 km

Every 3,728 mi

1 item

Replace oil filter

Engine

Factory

Manual: Change oil filter element. Factory: Chart p.180: initial 800 km, then every 6,000 km

Every 4,000 mi or 12 months

1 item

Replace spark plugs

Engine

Guideline

Every 5,000 mi or 2 years

1 item

Check cylinder head bolt torque

Engine

Guideline

Air-cooled iron and alloy engines can lose head bolt tension; follow your manual's sequence and whether it is done hot or cold.

Every 6,000 mi or 12 months

4 items

Clean carburetor float bowl(s), check float level and jets

Fuel and air

Guideline

Ethanol fuel varnishes old carbs quickly in storage.
Check charging voltage and regulator / cut-out

Ignition and electrics

Guideline
Check swingarm bushes for play

Rear suspension and frame

Guideline
Inspect rear shocks for leaks and damping

Rear suspension and frame

Guideline

Every 6,000 mi or 2 years

1 item

Check engine breather and oil return

Engine

Guideline

Every 6,214 mi or 12 months

1 item

Replace brake fluid

Brakes

Factory

Manual: Change brake fluid. Factory: Chart p.180: every year or 10,000 km

Every 6,214 mi

5 items

Replace air filter element

Fuel and air

Factory

Manual: Change air cleaner element. Factory: Chart p.180: every 10,000 km or after cleaning 5 times
Lubricate and check automatic advance unit

Ignition and electrics

Factory

Manual: Lubricate timing advancer. Factory: Chart p.180: every 10,000 km
Change fork oil

Front end

Factory

Manual: Change front fork oil. Factory: Chart p.180: every 10,000 km
Check steering head bearing adjustment

Front end

Factory

Manual: Check steering play. Factory: Chart p.180: initial 800 km, then every 10,000 km
Check brake pads and discs

Brakes

Factory

Manual: Check brake wear. Factory: Chart p.180: every 10,000 km

Every 10,000 mi or 2 years

1 item

Compression test (or leak-down)

Engine

Guideline

Every 12,000 mi or 3 years

1 item

Replace points and condenser

Ignition and electrics

Guideline

Every 12,427 mi or 2 years

4 items

Repack / replace steering head bearings

Front end

Factory

Manual: Lubricate steering stem bearings. Factory: Chart p.180: every 2 years or 20,000 km
Lubricate brake cam spindles, check linings and drums

Brakes

Factory

Manual: Regrease brake camshaft. Factory: Chart p.180: every 2 years or 20,000 km
Repack / replace wheel bearings

Wheels and tires

Factory

Manual: Regrease wheel bearings. Factory: Chart p.180: every 2 years or 20,000 km
Lubricate speedometer / tachometer cables, check drive

Controls and cables

Factory

Manual: Regrease speedometer gear housing. Factory: Chart p.180: every 2 years or 20,000 km

Every 15,000 mi or 5 years

1 item

Inspect clutch plates and springs

Primary and gearbox

Guideline

Every 15,000 mi

1 item

Replace brake linings / skim drums (wear based)

Brakes

Guideline

Every 25,000 mi or 6 years

1 item

Replace swingarm bushes / bearings

Rear suspension and frame

Guideline

Every 30,000 mi or 6 years

1 item

Rebuild forks: seals, bushes, springs

Front end

Guideline

Every 6 months

1 item

Clean battery terminals, check charge and strap

Ignition and electrics

Guideline

Every 12 months

1 item

Check speedometer / odometer against a known distance

Controls and cables

Guideline

Old speedos drift with tire size and drive wear. Use phone GPS over a measured 10 miles / km.

Every 2 years

3 items

Inspect fuel tank for rust, sealer failure, leaks

Fuel and air

Guideline
Inspect wiring, bullet connectors and ground points

Ignition and electrics

Guideline
Inspect frame, welds and lugs for cracks

Rear suspension and frame

Guideline

Every 4 years

3 items

Replace fuel lines

Fuel and air

Guideline

Old rubber and modern ethanol fuel do not mix well.
Inspect brake hoses; replace old rubber

Brakes

Guideline
Rebuild calipers and master cylinders (seals)

Brakes

Guideline

Every 6 years

2 items

Replace inner tubes and rim tape with tires

Wheels and tires

Guideline
Replace tires on age (regardless of tread)

Wheels and tires

Guideline

Guideline lines: Intervals here are general guidelines for the machine's era and layout, compiled for this app. They are not factory manual figures. Check your workshop manual, and edit any interval in the bike's Schedule tab.