Kawasaki Z400 - Service manual > Balancer

Balancer Removal

• Split the crankcase (see Crankcase Splitting).
• Remove the balancer shaft [A] with the balancer gear.

Balancer installation

• Apply molybdenum disulfide oil solution to the balancer shaft beating inserts.
• Install the balancer shaft [A].

Align the timing mark [B].

Crankshaft [C]

• Assemble the crankcase (see Crankcase Assembly).

Balancer Shaft Bearing Insert/Journal Wear Inspection

• Measure the bearing insert/journal [A] clearance with plastigage [B]

NOTE

• Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
• Do not turn the balancer shaft during clearance measurement.
• Journal clearance less than 0.025 mm (0.00098 in. ) can not be measured by plastigage, however; using genuine parts maintains the minimum standard clearance.

Balancer Shaft Bearing Insert/Journal Clearance

Standard: 0.024 ~ 0.048 mm (0.0009 ~ 0.0019 In.)

Service Limit: 0.08 mm (0.0031 in.)

*If the clearance is within the standard, no bearing replacement is required.

*If the clearance is between 0.048 mm (0.0019 in.) and the service limit 0.08 mm (0.0031 in.), replace the bearing inserts [A] with inserts painted blue [B]. Check insert/journal clearance with the plastigage. The clearance may exceed the standard slightly, but it must not be less than the minimum in order to avoid bearing seizure.

*If the clearance exceeds the service limit, measure the diameter of the balancer shaft journal.

Balancer Shaft Journal Diameter

Standard: 25.984 - 26.000 mm (1.0230 - 1.0236 In.)

Service Limit: 25.96 mm (1.022 in.)

*If any journal has worn past the service limit, replace the balancer shaft with a new one.

*If the measured journal diameters are not less than the service limit, but do not coincide with the original diameter markings on the balancer shaft, make new marks on it.

Balancer Shaft Journal Diameter Marks

None: 25.984 - 25.992 mm (1.0230 - 1.02331 In.)

: 25.993 - 28.000 mm (1.02334 - 1.0236 in.)

: Balancer Shaft Journal Diameter Marks, "O" or no mark.

• Measure the main bearing inside diameter, and mark the upper crankcase half in accordance with the inside diameter.

[A]: Balancer Shaft Bearing Inside Diameter Marks, "O" or no mark.

NOTE

• Tighten the crankcase bolts to the specified torque (see Crankcase Assembly).
• The mark already on the upper crankcase half should almost coincide with the measurement.

Balancer Shaft Bearing Inside Diameter Marks

: 29.000 - 29.008 mm (1.1417 - 1.1420 in.)

None: 29.009 - 29.016 mm (1.1421 - 1.1424 in.)

• Select the proper bearing insert [A] in accordance with the combination of the crankcase and balancer shaft coding.

  Size Color [B]

• Install the new inserts in the crankcase and check insert/journal clearance with the plastigage.

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