2003-2004 Kawasaki KFX400 All Terrain Vehicle Service Manual
This manual details servicing and overhaul procedures for the Kawasaki KFX400, KFX400-A1, and KFX400-A2 models. It covers engine, chassis, fuel, and electrical systems. P/N 99000-11550-041
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Models Covered & Key Technical Specifications
Detailed Overhaul Installation Manual: Kawasaki KFX400, KFX400-A1 & KFX400-A2 (2003-2004) Engineering-Archive Service Manual | Reference Data Documented Heat Dissipation: 398 mL (24.3 cu in) is the engine's displacement capacity. Technical Production Rate: The transmission features a 5-speed and 1-reverse gear system. Universal Form Factor: The chassis is constructed with a double tubular frame. Maximum Tightening Data: The rear axle locknut (outside) requires 180 N-m for proper torque. System Gap Specs: Valve clearance for the intake is 0.10–0.20 mm. Prescribed Working Temperature: The cooling fan thermo-switch operates at approximately 88°C (190°F).
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Detailed Overhaul Installation Manual: Kawasaki KFX400, KFX400-A1 & KFX400-A2 (2003-2004) Engineering-Archive
| Model-Designation: KFX400, KFX400-A1, KFX400-A2 // Technical-Benchmarks: ATV / Engine Logic // Model-Designation: 2003-2004 | Assessment-Element | Technical-Path | Context |
|---|---|---|---|
| Engine Displacement | 398 mL (24.3 cu in) | Specifies the cubic inch volume of the engine. | |
| Transmission Type | 5-speed and 1-reverse | Details the gearbox configuration. | |
| Frame Construction | Double Tubular | Describes the primary structural material. | |
| Rear Axle Locknut Torque | 180 N·m | Ensures secure axle housing. | |
| Intake Valve Clearance | 0.10–0.20 mm | Critical for proper engine timing. | |
| Cooling Fan Thermo-Switch | 88°C (190°F) | Sets the fan engagement temperature. |
Major sections focus on engine disassembly and reassembly, including detailed procedures for the cylinder head, crankshaft, and transmission gears. This manual provides a comprehensive overview of the cooling and lubrication systems, detailing radiator maintenance, water pump repair, and oil flow. Additionally, it covers chassis components such as suspension, steering, and brakes, along with the electrical system and fuel system maintenance for the carburetor. Torque specifications are documented throughout for critical fasteners to ensure proper assembly and gasket seal integrity.
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