1980-1982 Kawasaki KZ440 Service Manual

Description

This 318 page 1980-1982 Kawasaki KZ440 Factory Service Manual provides detailed service information, step-by-step repair instruction and maintenance specifications for 1980-1982 Kawasaki KZ440 motorcycles. This  workshop manual is out of print and available as a high quality reproduction only.

KZ440 Repair Manual Table of Contents:

Specifications

Specifications, Engine performance curves, Running performance curves, periodic maintenance chart.

Engine Adjustment

SPARK PLUGS, IGNITION TIMING, VALVE CLEARANCE, THROTTLE CABLE, CARBURETORS, CLUTCH, ENGINE OIL, FUEL SYSTEM

Adjustment of Chassis

REAR SHOCK ABSORBERS, DRIVE CHAIN (KZ440-A, B, C), DRIVE BELT (KZ440-D), BRAKES; Front Brake (KZ440A, C), Front Brake (KZ440B), Rear Brake, BRAKE LIGHT SWITCH, STEERING, WHEEL BALANCE, HEADLIGHT, AUTOMATIC SIDE STAND RETURN MECHANISM, LUBRICATION

Disassembly of Engine

FLOW CHART, AIR CLEANER ELEMENT, FUEL TANK, FUEL TAP, IGNITION COIL, CARBURETORS, MUFFLERS, TOP END (CYLINDER HEAD COVER, ROCKER ARM, ROCKER SHAFT, CAMSHAFT CHAIN TENSIONER CAMSHAFT, CAMSHAFT SPROCKET, CYLINDER HEAD, VALVE, VALVE GUIDE, CYLINDER BLOCK, CAMSHAFT CHAIN GUIDE (Rear), PISTON, PISTON RINGS, OIL PIPE, OIL PRESSURE SWITCH), LEFT SIDE (ENGINE SPROCKET (or PULLEY) COVER, CLUTCH RELEASE, NEUTRAL SWITCH, ENGINE SPROCKET (or PULLEY), ALTERNATOR STATOR, ALTERNATOR ROTOR, STARTER MOTOR, CLUTCH, STARTER MOTOR CHAIN, SPROCKETS, STARTER MOTOR), RIGHT SIDE (CONTACT BREAKER, CAPACITOR, TIMING ADVANCER, PRIMARY CHAIN GUIDES, CLUTCH, PRIMARY CHAIN, PRIMARY SPROCKET, OIL PUMP DRIVE GEAR, OIL PUMP, OIL PRESSURE RELIEF VALVE, EXTERNAL SHIFT MECHANISM), BOTTOM END (OIL FILTER, BYPASS VALVE)

Disassembly—Engine Removed

FLOW CHART, ENGINE REMOVAL, CRANKCASE SPLIT, TRANSMISSION (Shift Drum, Drive Shaft, Output Shaft), BALANCER MECHANISM, MAIN BEARING CAP, CAMSHAFT CHAIN GUIDE (Front), CONNECTING ROD, CRANKSHAFT, CAMSHAFT CHAIN

Disassembly—Chassis

WHEEL, BRAKES, DRIVE CHAIN (BELT) FRONT WHEEL, FRONT DISC BRAKE, DRIVE CHAIN (KZ440A, B, C), DRIVE BELT (KZ440D), REAR WHEEL, REAR BRAKE, TIRE, TUBE, RIM, SPOKE, CABLES, FRONT BRAKE, CLUTCH, THROTTLE, SPEEDOMETER, TACHOMETER, LIGHTS, HEADLIGHT – INDICATOR LIGHTS, TURN SIGNAL LIGHT, TURN SIGNAL ASSEMBLY, SPEEDOMETER – METER LIGHT, TACHOMETER – METER LIGHT – INDICATOR LIGHTS, TAIL/BRAKE LIGHT, SWITCHES IGNITION, FRONT BRAKE LIGHT, REAR BRAKE LIGHT, STEERING – HANDLEBAR, STEERING STEM, STEERING STEM BEARING, SUSPENSION – FRONT, FORK, SWING ARM

Maintenance—Engine

AIR CLEANER, FUEL TANK, FUEL TAP, CARBURETORS, ROCKER ARMS, SHAFTS, CAMSHAFT, CAMSHAFT CHAIN, GUIDES, TENSIONER, CYLINDER HEAD, VALVES, CYLINDER BLOCK, PISTON, CRANKSHAFT, CONNECTING RODS, BALANCER MECHANISM, CLUTCH, PRIMARY CHAIN, TRANSMISSION, ENGINE LUBRICATION, BALL, NEEDLE BEARINGS, OIL SEALS, MUFFLERS

Maintenance—Chassis

WHEELS (Tires, Rims (cast wheels), Rims, Spokes (wire spoke wheels), Axle, Wheel Bearings, Grease Seals, Rear Wheel Coupling), DRIVE CHAIN (KZ440A, B, C), SPROCKETS (KZ440A, B, C), DRIVE BELT (KZ440D), PULLEYS (KZ440D), DISC BRAKE (KZ440A, C, D), DRUM BRAKE, STEERING STEM, FRONT FORK, REAR SHOCK ABSORBERS, SWING ARM, AUTOMATIC SIDE STAND RETURN MECHANISM

Maintenance-Electrical

BATTERY, CHARGING SYSTEM – Alternator, Regulator/Rectifier, IGNITION SYSTEM – Ignition Coil, Contact Breaker, Capacitor, Timing Advancer, Spark Plugs, ELECTRIC STARTER SYSTEM – Starter Motor Circuit, Starter Motor, Starter Motor Clutch, Chain, IGNITION SWITCH, NEUTRAL SWITCH, LIGHTING SYSTEM – Headlight Circuit, Brake Light Circuit, Turn Signal Circuit, HORN, SPEEDOMETER, TACHOMETER

Troubleshooting Guide

Special Tools

Wiring Diagrams