Kawasaki Z400 - Service manual > Oil Pump

Oil Pump Removal

• Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pump Driven Gear Bolt [A] Oil Pump Driven Gear [B] Hold the gear steady with the gear holder [C].

Special Tool - Gear Holder. 57001-1602

• Remove: Oil Pump Cover Bolts [A] Oil Pump Cover [B]

• Remove: Oil Pump Shaft [A] Inner Rotor [B] Pin Outer Rotor [C]

Oil Pump Installation

• Apply molybdenum disulfide oil solution Oil Pump Shaft [A] Inner Rotor [B] Outer Rotor [C]
• Assemble: Oil Pump Shaft Pin [D] Inner Rotor

Fit the groove of rotor and the pin.

• Install the outer rotor into the crankcase.
• Install the inner rotor and shaft.
• Be sure to install the dowel pins [A]
• Install the oil pump cover [B].
• Apply a non-permanent locking cover bolts.
• Tighten: Torque -  oil Pump Cover Bolts: 7.0 N*m (0.71 kgf*m, 62 In-lb)

• Install the oil pump driven gear [A] onto the oil pump shaft [B] with its projecting side [C] Facing to the oil pump.

• Apply a non-permanent locking agent to the threads of W the oil pump driven gear mounting bolt [A].
• Hold the oil pump driven gear [B] steady with the clutch holder [C], and tighten the dl pump driven gear bolt.

Special Tool - Gear Holder: 57001 -1 602 Toque - Oil Pump Driven Gear 8dt: 9.8 Nm (1.0 kgf*m, 87 In*lb)

Oil Pressure Measurement

Remove the right lower fairing (see Lower Fairing Removal in the Frame chapter).

Remove the oil passage plug [A].

• Attach the adapter [A] and gauge [B] to the plug hole.

Special Tools- Oil Pressure Gauge, 10 kgf/cm²: 57001 -164

Oil Pressure Gauge Adapter, PT 318: 57001 -1233

• Start the engine and warm up the engine.
• Run the engine at the specified speed, and read the oil pressure gauge.

*If the reading is much lower than the standard, check the oil pump, relief valve, and/or crankshaft bearing insert wear immediately.

*If the Wing is much higher than the standard, check the oil passages for dogging.

Oil Pressure Standard: 157 - 206 kPa (1.60 - 2.10 kgf/cm², 22.8 - 29.9 psi) @4 000 r/min (rpm), Oil Temperature 90ºC (194OF)

• Stop the engine.
• Remove the oil pressure gauge and adapter.

Apply a non-permanent locking agent to the dl passage plug, and install it.

Tighten: Toque - oil  Passage Plug: 20 N*m (2.0 kgf*m, 15 ft*lb)

Install the right lower fairing (see Lower Fairing Installation in the Frame chapter).

Oil Pressure Switch Removal

• Drain: Engine Oil (see Engine Oil Change in the Periodic Maintenance chapter)
• Remove: Right Lower Fairing (see Lower Fairing Removal in the Frame chapter) Switch Cover [A] Switch Terminal Bolt [B] Oil Pressure Switch [C]

Oil Pressure Switch Installation

• Clean off any oil or dirt and apply silicone sealant to the threads of the oil pressure switch and tighten it.

Sealant - Liquid Gasket, TB1211: 56019-120

Torque - OH Pressure Switch: 15 N-m (1.5 kgf-m, 11 R-lb)

• Apply grease to the both sides of the switch lead terminal.
• Connect the switch lead [A] to the switch terminal as shown

NOTE

Apply a small amount of grease to the terminal so that grease should not dose two breather holes [A] for switch diaphragm.

• Install: switch Cover Right Lower Fairing (see Lower Fairing Installation in the Frame chapter)
• Fill the engine with engine dl (see Engine Oil Change in the Periodic Maintenance chapter).

Oil Pipe Removal

• Remove: Clutch (see Clutch Removal in the Clutch chapter) Oil Pipe Bolt [A] oil Pipe [B]

Oil Pip Installation

• Installation is the reverse of removal.
• Tighten: Toque -Oil Pipe Bolt: 9.8 N-m (1.0 kgf-m, 87 in*lb)

See also: