Kawasaki Z400 - Service manual > Electrical System

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5. Equipped Models

G: Apply grease.

L: Apply a non-permanent locking agent.

LG: Apply liquid gasket.

M: Apply molybdenum disulfide grease.

MO: Apply molybdenum disulfide oil solution.

(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:l)

R: Replacement Parts

S: Follow the specified tightening sequence.

L: Apply a nonpermanent locking agent.

R: Replacement Parts

S: Follow the specified tightening sequence.

Specifications

Special Tools and Sealant

Flywheel Holder: 57001 -1313

Flywheel Puller Assembly, M38*1.5/M35*1.5:57001-1405

Peak Voltage Adapter: 57001 -1415

Lead Win - Peak Voltage Adapter: 57001 -1 449

Needle Adapter Set: 57001 -1 874

Liquid Gasket, TB1211F: 92104-0004

Parts Location

Starter Lockout Switch [A] Accessory Socket [B] (Equipped Models) Meter Unit [C] Front Brake Light Switch [D] Ignition Switch [E]

Horn [A]

Regulator/Rectifier [B]

Accessory Relay [C] (Equipped Models)

Turn Signal Relay [D]

Water Temperature Sensor [A] Starter Motor [B] Gear Win Sensor [C] Side Stand Switch [D] Crankshaft Sensor [E] Alternator [F]

Fuse Box (1) [A] Fuse Box (2) [B]

Radiator Fan Motor [A] Air Switching Valve [B] Stick Coils [C] Spark plugs [D]

Relay Box [A] Battery [B] ECU [C] Starter Relay [D]

Oil Pressure Switch [A] Oxygen Sensor [B]

Rear Brake Light Switch [A]

Fuel Level Sensor [A]

Wiring Diagram (EX400G/J)

Wiring Diagram (EX400H)

Precautions

There are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below.

• Do not reverse the battery cable connections. This will bum out the diodes on the electrical parts.
• Always check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests.
• The electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the parts can damage them.
• To prevent damage to electrical parts, do not disconnect the battery cables or any other electrical connections when the ignition switch is on, or while the engine is running.
• Because of the large amount of current, never keep the starter button pushed when the starter motor will not turn over, or the current may bum out the starter motor windings.
• Take care not to short the cables that are directly connected to the battery positive (+) terminal to the chassis ground.
• Troubles may involve one or in some cases all items.

  Never replace e defective part without determining what CAUSED the failure. If the failure was caused by some other item or items, they must be repaired or replaced, or the new replacement will soon fail again.

• Make sure all connectors in the circuit are dean and tight, and examine wires for signs of burning, fraying, etc. Poor wires and bad connections will affect electrical system operation.
• Measure coil and winding resistance when the part is cold (at mom temperature).

 Electrical Wiring

Wiring Inspection

• Visually inspect the wiring for signs of burning, fraying, etc.

*If any wiring is poor, replace the damaged wiring

• Pull each connector [A] apart and inspect it for corrosion.

  dirt, and damage

*If the connector is corroded or dirty, clean it carefully. if it is damaged, replace it

• Check the wiring for continuity
• Use the wiring diagram to find the ends of the lead which is suspected of being a problem.
• Connect a tester between the ends of the leads
• *If the tester does not read about 0 , the lead is defective.

  Replace the lead or the wiring harness if necessary.

• Battery
• Charging System
• Ignition System
• Electric  Starter System
• Lighting System
• Air Switching Valve
• Meter, Gauge, Indicator Unit
• Switches and Sensors
• Relay Box

See also: