Kawasaki KFX 400 Service Manual Repair 2003-2006 KFX400

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The Kawasaki KFX400 is a performance sport ATV produced from 2003 to 2006, sharing its platform and mechanical design with the Suzuki LT-Z400. This model is recognized for its robust...

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UGS: 142348

Mots clés: 2003 2004 2005 2006 ATV Kawasaki KFX 400 KFX Models Powersports

Variantes de produits

Description

The Kawasaki KFX400 is a performance sport ATV produced from 2003 to 2006, sharing its platform and mechanical design with the Suzuki LT-Z400. This model is recognized for its robust 398 cc liquid-cooled, single-cylinder engine, delivering approximately 37.7 hp, and its 5-speed manual transmission with reverse. Engineered for enthusiasts and recreational riders, the KFX400 features a liquid-cooled engine, hydraulic disc brakes, and a capable suspension system, making it a competitive choice in its segment. Its durable steel frame and off-road focused design ensure reliability and performance across various terrains. This comprehensive Factory Service Manual provides detailed repair and maintenance information for the Kawasaki KFX400 models from 2003 through 2006. It covers all major systems, including the engine, transmission, chassis, suspension, brakes, and electrical systems, with in-depth procedures for complete tear-downs and rebuilds. The manual includes scheduled maintenance intervals, troubleshooting guides, technical specifications, and detailed diagrams to assist owners and technicians in maintaining and repairing the vehicle effectively. Its scope ensures that both routine upkeep and complex repairs can be addressed with accuracy and confidence.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KFX400

Model Codename:

KFX400 (Shares platform/design with Suzuki LT-Z400)

Vehicle Type:

ATV (All-Terrain Vehicle)

Codes

Chassis Code:

KFX400-A1, KFX400-A2, KFX400-A3, KFX400-A4 (Specific to Kawasaki model years)

👋 Introduction

Market Position

Market Segment:

Performance Sport ATV

Target Audience:

Enthusiasts, recreational riders, and service technicians seeking in-depth repair and maintenance information.

Competitive Analysis

Key Competitors:

Suzuki LT-Z400 (sharing identical mechanicals), Yamaha Raptor 350, Honda TRX300EX/400EX.

Key Features

Shared Platform:

Highlights the close relationship and shared components with the Suzuki Z400, making this manual highly relevant for both models.

Completeness:

Promises comprehensive coverage, including diagrams, torque specs, and troubleshooting, fulfilling the needs of a complete workshop manual.

📋 Manual Details

Coverage Areas

Covered Years:

2003, 2004, 2005, 2006

Coverage Description:

Comprehensive repair and service for the Kawasaki KFX400. Includes detailed information on the shared Suzuki LT-Z400 platform with a Kawasaki supplement. Covers complete tear down and rebuild procedures.

Page Count

Page Count:

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

File Format:

📖 Manual Coverage

Systems Covered

Engine System:

Complete engine overhaul, internal components, lubrication, cooling system, starting system, ignition system, fuel system (carburetor).

Transmission System:

Clutch operation, gearbox inspection and repair, final drive, chain maintenance.

Chassis Suspension Steering:

Front and rear suspension components, shock absorbers, steering column, tie rods, hub assemblies.

Brakes:

Front and rear brake system components, hydraulic lines, caliper service, rotor inspection, brake fluid specifications.

Electrical System:

Wiring diagrams, battery service, lighting system, ignition system troubleshooting, starter motor, charging system.

Body Frame Trim:

Frame inspection, body panel removal and installation, seat, fenders, plastics.

Procedures Included

Maintenance:

Scheduled maintenance intervals, oil changes, filter replacements, chain adjustment, spark plug service, brake system bleeding.

Troubleshooting:

Diagnostic charts and procedures for common and uncommon issues, fault finding for engine, electrical, and mechanical problems.

Repair Rebuild:

Complete disassembly and reassembly instructions for all major components, including engine internal rebuilds.

Technical Specifications:

Torque specifications for all fasteners, engine clearances, fluid capacities, tire pressure recommendations.

Diagrams Illustrations:

Detailed part diagrams and exploded views for component identification and assembly order. Step-by-step illustrations for key procedures.

Technical Depth

Depth Of Coverage:

Comprehensive. Covers everything from basic owner maintenance checks to full engine rebuilds and advanced electrical system diagnostics.

📊 Manual Specifications

File Specifications

Compatibility:

All Versions of Windows & Mac

Accessibility:

Downloadable

Required Software:

Adobe PDF Reader

Print Quality

Print Quality:

High-resolution PDF suitable for printing individual pages or the entire manual.

Binding Type

Binding Type:

Digital (PDF download)

Paper Type

Paper Type:

N/A (Digital file)

⚙️ Engine Specifications

Primary Engine

Engine Type:

4-stroke, Single Cylinder, DOHC, 4 valves

Displacement:

398 cc (24.3 cu in)

Bore X Stroke:

90.0 x 78.5 mm

Cooling System:

Liquid-cooled

Performance

Horsepower:

Approx. 37.7 hp @ 7500 rpm (Manufacturer data may vary)

Torque:

Approx. 27.7 lb-ft @ 6000 rpm (Manufacturer data may vary)

Fuel System

Fuel Delivery:

Mikuni BSR36 (Single Carburetor)

Carburetor Details:

36mm constant velocity carburetor with accelerator pump.

Lubrication

Oil Type:

SAE 10W-40 API SG or SH

Oil Capacity:

1.9 L (2.0 US qt) with filter change

🔧 Transmission

Standard

Transmission Type:

5-speed manual with reverse

Clutch Type:

Wet, multi-disc

Features

Final Drive:

O-ring sealed chain, 520 pitch

Gear Ratios:

Specific gear ratios detailed within the manual.

📐 Dimensions

Exterior

Overall Length:

1830 mm (72.0 in)

Overall Width:

1130 mm (44.5 in)

Overall Height:

1085 mm (42.7 in)

Wheelbase:

1270 mm (50.0 in)

Ground Clearance:

260 mm (10.2 in)

Weights

Dry Weight:

170 kg (375 lbs)

Curb Weight:

N/A (Dry weight is commonly listed)

Fuel Tank Capacity:

9.0 L (2.4 US gal)

🛡️ Safety Features

Ratings

Safety Ratings:

ATVs are not subject to the same federal crash safety ratings as passenger vehicles; user responsibility and safe operating practices are paramount.

Active Features

Braking System:

Hydraulic disc brakes front and rear.

Throttle Limiter:

Not typically present on performance ATVs of this era; rider skill is key.

Passive Features

Chassis Design:

Tough steel frame and bodywork designed for off-road abuse.

💡 Technology Features

Infotainment

Infotainment System:

None (Basic instrumentation: speedometer, odometer, neutral indicator, high-beam indicator).

Driver Assistance

Driver Assistance:

None (Focus on mechanical and engine systems).

Connectivity

Connectivity Features:

None.

🔧 Maintenance

Service Intervals

Engine Oil Change:

Every 100 hours or 6 months, whichever comes first. (Refer to manual for exact hours/miles).

Air Filter Cleaning:

Clean every 20 hours or 3 months, replace as needed. More frequent cleaning in dusty conditions.

Spark Plug Inspection:

Inspect every 100 hours or 6 months. Replace as needed based on condition.

Chain Lubrication Adjustment:

Lubricate every 20 hours or monthly. Adjust slack every 20 hours or monthly.

Valve Clearance Check:

First check at 100 hours, then every 200 hours or annually.

Fluid Specifications

Engine Oil Specification:

SAE 10W-40 API SG or SH, JASO MA certified motorcycle oil.

Coolant Type:

Permanent type anti-freeze, 50/50 mixture with distilled water.

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid.

Transmission Gear Oil:

Specific gear oil type and quantity detailed in the manual, typically a hypoid gear oil for the final drive.

Known Issues

Common Issues:

Carburetor jetting issues (can be lean from factory), occasional starter motor issues, wear on chain and sprockets, suspension wear from aggressive riding.

Performance Tuning:

The manual will provide baseline settings for the Mikuni BSR36 carburetor, which is often a target for aftermarket tuning for improved performance.

📚 Vehicle History

Brand Heritage

Kawasaki Atv History:

Kawasaki has a long history in powersports, including a significant presence in the ATV market with models like the Bayou and later performance-oriented machines.

Model Evolution

Kfx400 Development:

Developed in collaboration with Suzuki, leveraging the successful Z400 platform. Positioned as a competitive sport ATV for racing and recreational trail riding.

Production

Production Period:

2003-2006 (for this specific model designation).

Manufacturing Location:

Primarily manufactured by Suzuki for both brands.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

The KFX400 and its Suzuki counterpart were well-regarded in their segment for their performance and handling, contributing to the growth of the sport ATV market.

Ratings

Performance Reviews:

Consistently reviewed as a strong performer, offering a good balance of power, suspension, and agility for its class.

Certifications

Certification Standards:

N/A for aftermarket service manuals in terms of formal certification.