Kawasaki Z400 - Service manual > Fenders

Front Fender Removal

• Remove: Reflector (Equipped Models, Both Sides) Bolt [A] with Collar and Washer (Both Sides) Bolt [B] (Both Sides) Bracket [C] Front Fender [D]

Front Fender Installation

• Installation is the reverse of removal.

Flap Removal

Remove the rear seat (see Rear Seat Removal).

Open the compartment cover.

Slide the cover [A].

Disconnect each connectors [B].

Free the connector leads from the damper [C].

• Remove the bob [A] and flap assembly.

Flap Installation

• Install the flap assembly.
• Tighten the bolts following the specified tightening sequence [1 - 4].
• Run the hose$, leads and harness correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Flap Disassembly/Assembly

Remove: Bolts [A] Collars [B] Bracket [C] Grommet [D] Flap [E] Turn Signal Lights License Plate Light

• Assembly is the reverse of removal.
• Run the cables, leads, harness and hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Rear Fender Removal

• Remove : Center Seat Cover (see Center Seat Cover Removal) Flap (see Flap Removal) Bands [A] Owner's Tool [B] Bolt [C] Bracket [D]
• Disconnect the brake/tail light lead connector [E]
• Open the band

• Free the  brake/tail light lead from the damper [A].
• Remove: Bolts [B] Bolts [C] and Washers Screws [D]
• Remove the rear fender backward.

Rear Fender Installation

• Check that the Gollars [A] are in place.
• Install the mar fender.
• Run the cables, leads, harness and hose cornectly (see cable, Wire, and Hose Wng seGiion in the Appendix chapter)
• Pull the rear part of the rear fender to outside while tightening the screws [A].
• Tighten the rear bolts [B] first, and then tighten the front bolts [C].

Battery Case Cover Removal

• Remove: Fuel Tank (see Fuel Tank Removal in the Fuel System (DFI) chapter) -, .

  Battery (see Battery Removal in the Electrical System chapter) Fuel Tank Bracket Bolts [A] Fuel Tank Bracket [B]

• Disconnect the intake air temperature sensor connector [A].
• Remove: Rear Wheel Rotation Sensor Lead Connector [B] Fuel Pump Lead Connector [C]
• Clear the leads from the battery case cover [D]
• Remove the bolts [E]
• Pull up the front part of the battery case cover, and remove it.

Battery Case Cow Installation

• Installation is the reverse of removal.
• Install the fuel tank bracket [A].
• Run the cables, leads, harness and hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).
• Tighten the fuel tank bracket bolts following the specified tightening sequence [1~4].

Battery Case Removal

• Remove: Rear Fender (see Rear Fender Removal) Battery Case Cover (see Battery Case Cover Removal) Bolt [A]

• Open the damp [A].

• Remove the bolt [A].

• Remove: Relay [A] ECU PI
• Open the damp [C].

• Remove the bolts [A] and washers.
• Push down the battery case to dear the tabs [B].
• Remove the battery case backward.

Battery Case Installation

• Installation is the reverse of removal.
• Run the cables, leads, harness and hose correctly (see Cable, Wire, and Hose Routing section in the Appendix chapter).

Frame

Frame Inspection

• Visually inspect the frame for cracks, dents, bending, or warp.

*If there is any damage to the frame, replace it.

WARNING

A repaired frame may fail in use, possibly causing an accident resulting in injury or death. If the frame I is bent, dented, cracked, or warped, replace it.

Rear Footpeg Bracket lnstallation

• Install the rear footpeg bracket [A].
• Tighten the rear footpeg bracket bolt (rear) [B] first, and then tighten the rear footpeg bracket bolt (front) [C].

Toque - Rear Footpeg Bracket Bolts: 25 N-m (2.5 kgf-m, 18 ft-lb)

• Install the removed parts (see appropriate chapters).

See also: