2003-2006 Kawasaki KFX400 ATV service manual

Table of Contents

1. Introduction
2. Specifications

• 2.1 Engine
• 2.2 Fuel system
• 2.3 Ignition system
• 2.4 Gearbox
• 2.5 Cutting attachment
• 2.6 Special accessories
  • 2.6.1 For the user
  • 2.6.2 For service
• 2.7 Tightening torques
  3. Clutch
• 3.1 Disassembly
• 3.2 Assembly
  4. Engine
• 4.1 Muffler / spark arresting screen
• 4.2 Leakage testing
  • 4.2.1 Preparations
  • 4.2.2 Pressure test
  • 4.2.3 Vacuum test
• 4.3 Oil seals
• 4.4 Exposing the cylinder/spacer flange
• 4.5 Cylinder and piston
  • 4.5.1 Removal
  • 4.5.2 Installation
• 4.6 Piston rings
• 4.7 Crankcase
  • 4.7.1 Removing the crankshaft
  • 4.7.2 Installing the crankshaft
    5. Ignition system
• 5.1 Spark plug terminal
• 5.2 Ignition module
  • 5.2.1 Ignition timing
  • 5.2.2 Removal and installation
• 5.3 Flywheel
  6. Rewind starter
• 6.1 General
• 6.2 Starter cover
• 6.3 Rewind spring
  • 6.3.1 Replacement
  • 6.3.2 Tensioning
• 6.4 Starter rope (ElastoStart)
• 6.5 Starter grip (ElastoStart)
• 6.6 Starter carrier/pawl
  7. Throttle control
• 7.1 Throttle trigger/interlock lever (throttle cable with one short-circuit wire)
• 7.2 Throttle cable with one short-circuit wire
• 7.3 Contact spring/detent spring in control handle (throttle cable with one short-circuit wire)
• 7.4 Throttle trigger/interlock lever (throttle cable with two short-circuit wires)
• 7.5 Throttle cable with two short-circuit wires
• 7.6 Adjusting the throttle cable
  8. Fuel system
• 8.1 Air filter
• 8.2 Carburetor
  • 8.2.1 Leakage testing
  • 8.2.2 Removal and installation
  • 8.2.3 Adjustment (two adjusting screws)
  • 8.2.4 Adjustment (one adjusting screw)
• 8.3 Tank vent
• 8.4 Pickup body
• 8.5 Fuel tank/hoses
  9. AV system
• 9.1 Repair
  10. Shaft
• 10.1 Cowhorn handle
• 10.2 Looped handle
• 10.3 Drive shaft/insulating tube
• 10.4 Protective tube
  11. Cutting tool drive
• 11.1 Bearing housing (FS 75)
• 11.2 Gearbox (FS 80, 85)
• 11.3 Gearbox (FC 75)
• 11.4 Clutch drum
  12. Cutting device (HL 75)
• 12.1 Gearbox
• 12.2 Cutting blade
• 12.3 Gearwheel
  13. Special service tools and aids
• 13.1 Special tools
• 13.2 Servicing aids

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