FIRSTISSUED 10-24-75 (Kz-8) Page 1 of 6 FACTORY DIRECTED Mo! Ee IEPAIR AS REQUIRED u | This procedure obsoletes and cancels the one described in Bulletin K2-8 (Job Code X049), DO 2] NOT perform the modification as directed in KZ-8, or request warranty reimbursement for Job Se| Code xoa3. st Refer to Bulletin 4/400-14 for detailed parts information ge 63] PROBLEM: FACTORY ACTION: TOP END OIL LEAKS DESIGN NEW SEALING COMPONENTS Some KZ400 owners have experienced oil The sealing components in these areas have leaks on their motorcycles. These leaks can been redesigned, changed to materials of iginate from one or more of the following loca- higher heat resistance, or otherwise improved. tions at the top end of the engine. Also, some parts (marked * below) have been 4, Cylinder Studs upgraded since this bulletin was first issued. 2. Cylinder Base Gasket Gylinder Head Gasket Rocker Arm Shafts Camshaft End Caps Gylinder Head Gover Cam Chain Tensioner ‘Tachometer Drive Gear Guide Valve Adjustment Plugs REVISED O@rNOHEo —/ SEALING COMPONENTS ‘A Cylinder Stud B, Cylinder Base Gasket C.Valve Adjustment Plug O-ring D-*Valve Adjustment Plug E. Rocker Arm Shaft O-ring F. Tach. Drive Gear Guide O-ring G.Tach. Drive Gear Guide Gasket H.Tach. Drive Gear Guide Oil Seal 1 Tach. Drive Gear Guide J. *Camshaft End Gap K*Tensioner Cap O-ting L*Cam Chain Tensioner Gasket MOval Oil Passage O-ring N-¥Cylinder Head Gasket ©.0il Passage O-ring o *indicates newly upgraded parts. Bb This symbol identiDEALER ACTION: INSTALL NEW-STYLE COMPONENTS ON ELIGIBLE UNITS ELIGIBILITY REQUIREMENTS, (must meetail) 1. The motoreycle must be under warranty. 2. Before E/N K4E094289 (K2400D and A); or K4SE030021 (kz400S). 3, Oil leak must be evident at one of the listed fop end areas. 4, The motoroycle has not already received this modification (no punch mark by engine number). If an eligible KZ400 is leaking oll from any of the top ehd areas listed abave, install all new-style components according to the steps described here. NOTE: Refer to the KZ400 Shop Manual for disassembly/assembly procedures. Make certain all traces of old gaskel and sealant are cleaned off before reassembly. Do not apply silicone sealant to any parls except as specifically directed here, as it may obstruct oll passages and cause engine damage. 1, Remove the cylinder head, 2. Remove the cylinder. 8. Stuff clean rags into the openings in the crankcase (under the pistons) to prevent any foreign matter from entering. It should Rot be necessary to change the engine oil and filter. Thoroughly clean any dirt, gasket material, or sealant from all mating sur- faces, and clean off any oll that has leaked on the outside of the engine 4. The threaded holes for six of the cylinder studs may open into crankcase oil passages. To prevent oil leakage at these Studs, they must be removed and their threads sealed with Loctite. Heat the crankcase around the studs te loosen the factory locking agent. (Temporarily remove the rags from the crankcase openings while heating) Remove the four rear and two inside front cylinder studs and discard them, Thoroughly clean the crankcase stud holes. Apply Loctite Lock ‘n’ Seai (biue) to the threads of six new studs and install them in the crankcase. Torque the studs to 2.7 kg-m (20 ft-Ibs.). CYLINDER STUD (Crankcase end)6. Check that the cylinder head sleeve nuts turn freely on all studs. If the nuts bind on the studs, thread chasing of the nuts and/or studs will be required before accurate cylinder head torque readings can be obtained. Use an 8 x 1.25mm bottoming tap on the nuts and an 8 x 1.25 die on the studs. Thread clearance is correct when the nut will turn freely on the stud until no threads are visible. Install the fiber base gasket and two oil passage O-rings of the correct shape: D-seetion on early crankcases, round sec- tion on late crankcases (with machined O-ring seats). NOTE: See bulletin 4/400- 12 for details, Page 30f6 6. Install the cylinder. 9. Gheck the cylinder head for excessive warp as noted in the shop manual. Fit the new-style head gasket (pre-applied sea- fant) and the two knock pins into place on the cylinder. Use the two new-style "D section oval O-rings at the oil passages, installed with the flat side down. Do not apply sealant on or around the O-rings, as it may cause them to collapse into the oil Passages and restrict oil flow. Install the cylinder head and camshaft. 10. Remove the rocker arm shatts from the cylinder head cover. Discard the old O-rings, lubricate’ the naw-style O-rings and install one on each shait. Reinstall the rocker arm shafts with the punch marks facing inward. 11. Remove the tachometer cylinder head cover. Installation of the cylinder head cover the tachometer drive gear in place could result in damage to the gear or the camshatt, ye gear {rom the12, Discard the aluminum camshatt end caps. Also discard the large cylinder head cover O-ring, if fitted (none will be used). Apply clear silicone sealant all around the two new-style rubber camshaft end caps, and set them in place on the cylinder head with the tabs on the outside. Apply sealant to the APPLY rm SEALANT | j Page 40f 8 Install the cam chain tensioner using the new-style gasket (pre-applied sealant) and the new bolts and washers. Also use the new-style O-ring (smaller diameter) under the tensioner cap, 14. Slide the tachometer drive gear out of the tachometer gear guide, and discard ihe guide. Fit the new-style O-ring and oil seal to the new-style guide, and reinstall the as- sembly in the cylinder head cover. Fit the new gasket in place and reconnect the tachometer cable. e t 4 Pascet| 8MM GUIDE O-RING ‘OIL SEAL 13, 15, Adjust vaive clearance. When complete, discard the old adjustment plugs. and O-rings. Fit the new-style O-rings on thi four new-style adjustment plugs and insti them in the cylinder head cover. Start the engine, let it warm up for 5 minutes, and check for oil leaks. Allow the engine to cool completely. Retorque all the cyinder head nuts and bolts, following the sequence shown here, One at a time, loosen each bolt 1/2 turn, then tighten it to the specified torque. 16, mating Surface of the cylinder head cover. it there is an O-ring groove, fill it com- pletely. If not, make 2 4mm (3/16 in.) wide bead around the surface. Install four new O-rings in the cylinder head cover at the side stud holes and install the cover, Install the cylinder head sleeve nuts and bolts, tightening them progressively In the sequence shown. 9 ft-lbs. TIGHTENING SEQUENCE RETORQUE SEQUENCE (Reverse of Tightening Sequence)IDENTIFICATION OF REPAIR To identify the engine as having received this fepair, make a punch mark in the forward left corner of the engine number boss. Page $ of 6 WARRANTY INFORMATION: FACTORY DIRECTED MODIFICATION: REPAIR AS REQUIRED This is a factory directed modification only for eligible units (see Eligibility Requirements). Refer to the Warranty Policies and Procedures Manual for detailed Claim Type 3 instructions. WARRANTY REQUEST INFORMATION Claim Type: Job Code: 21053 Time, Hours: 4.3 99996-1004-02 CYLINDER HEAD RETORQUE Instruct the customer to return after approx- imately 500 miles of use, Retorque the cylinder head nuts and bolts at that time, following the procedure in step 16 above. Be sure the engine is completely cool. ores: 1, Warranty reimbursement may be requesied for performing this procedure on motorcy- cles still under original factory warranty. Authorization must be obtained in advance for repair of units out of warranty. Authoriza~ tion will be granted only under special condi- tions. Each case will be reviewed individually. 2, Use only Job Code 21053 for this repair, regardiess of the model year of the unit. 3. Warranty reimbursement for this repair will be made once only for any particular unit. Do not submit a claim on a unit that already has @ punch mark by the engine number. 4, Reimbursement for parts will be made on the basis of one kit, P/N 99996-1004-02, per claim, This is the only part that should appear on the warranty request, 5, The time allowance includes the 500 mile cylinder head nut retorque. 6. Warranty reimbursement will not be made for engine ollor filter. 7. Send in the warranty request immediately after installing the kit. Do not wait until after the 500 mile cylinder head retorque.PARTS INFORMATION: REQUIRED PARTS AREAVAILABLEIN A KIT All the parts required to repair one unit are con- tained in a top end sealing kil, P/N 99996- 1004-02. The kit contents are listed below. DESCRIPTION PUN oTY REMARKS: ‘ ey op End Sealing Kit 89990-1008.02| 1 | Containparte tiated below Siua Syinaer a2008-088 | insiawin Loctite tive) Gasket Cinder Gass 14009-040. 1 | Fiver Gasket wit ol passage G-ings) “ring Oilassane 2055-074 2 | b-Section teary | '92055-000, 2 ‘Round-Section (ate) | Gaskets 11004-1003 1 [- Shin Presappled Sealant ‘Gna. Oi Passene. Oval ‘nio08.012 2 | HieTemp Fourice (Vion! “0” Seaton “al ‘Grin. Rocker Am Sate 32055-008 4 [Herren Fourie (Viton) ‘rnin Cylinder Head Gaver 3e065:087 No Grange Cag, Cammhalt End 92075-086 22 | Rube. win Tab Gtshet Cam Chain Tensioner 12056-004 1527 | Preaonied Seaiani Washer, Tensioner Bal aroB0860, 2 [New Bol Teasnae ae00i-ti8 2 [ete ‘Orring. Tensioner Can 97058-104 1 | Revised Stape Guile, Tach Drive Gear 2067-011 1 | Revisea Snape ‘Oi Sent Tach Gear Guo 2050-075 1 _|_H-termn Fourie onl Gasket, Toot Deve Gear GigE Set0s-i08 [one ‘ring. Tach ri Gear Guide 2056-096 1__|-Histenp Fource onl Fig Valve Adustnent 2060-050 4 | Revised Shape Orrina Vaive Adusiment Pag 2056-097 a | Hiren Founda tion! Gisket Vale Adjustment Cover 11023-007 2 | No Gnange Gerng. yl Hene Broathor Cover 2055-064 + |" NoGtangs Gtskol Exhaust Pipe 16067.070 2 | to change Loci Lack W Seal (al 6078-001 1 __| fer Gyindar Stade ler Silicone Sealna x61079-007 7 NOTE: The parts ‘Apply (0 Gyl. Haad Cove’ and Camshall End Gaps: HY ted here are the latest designs, and are the only ones that should be used or kepi in stock, Old-style parts (earlier P/N's ~ see Bulletin 4/400-14 for a complete list) may be returned to area warehouses for credit, after notification from KMC.90996-1004-02 DESCRIPTION ary REMARKS Top End Sealing Kit Contains parts listed below Stud. Gylinder Tnatall with Loctite ive) 11909-040 Gasket. Cylinder Base Fiber Gasket (witholl passage O-ingsl '92055.074 (32055-0980) ing, Ol paseage D-Section feariy) 11008-1003. Gasket Cylinder Head 3. Pre-applied Sealant 11008-1012" ing, Ol Passage, Oval Hi-Temp Flouride (Viton) “D=Section '92085.098 (O-ring. Reeker Arm Shatt '32055.067, O-ring. Cylinder Head Gover ‘he Change 3|92073-095. Gap. Camshaft Ena Rubber, with Fab, 12066-0048 (Cam Chain Tensioner Pro-appied Sealer 41080600 S2001-114 Bolt Tensioner 313_|_o20ss-104 “O-ring Tensioner Gap. ta | 92087-018 "Guide, Tach Deve Gear {32050-0761 82005-1081 ‘Gasket Tach Drive Gear Guice 2055-006) 2086-086 “O-ring Tach Drive Gear Guide Pug. Valve Adjustrneat 13 | 92055-007 ‘O-ring. Valve Adjustment Ping HiTemp Flowide (Viton) 11025-007, ‘Gasket Vaive Adjustment Cover NeChange ‘This P/N is for reorder of equivalent sealant in 3 oz. tube. 32055-0864 ‘O-ring Gy Head Breather Cover No Change, 12067-020 No.Change, K61079-001 [Geeta Laek Ni Saal ive) For Cylinder Stade K6i07@-007" ‘Giear Siticone Sealant Apply te Gyi Head Cover and Camahal Gnd Capa ‘ONLY