Kawasaki Ninja 400 EX400GJ/HJ/JJ Motorcycle Service Manual – Complete Workshop Guide

Description

This Kawasaki Ninja 400 Motorcycle Service Manual is the complete workshop reference for the EX400GJ, EX400HJ and EX400JJ models, covering every major system from the DFI fuel injection and liquid-cooling circuits through to the trellis frame, braking hardware and ABS electronics. Across 653 pages the manual lays out step-by-step disassembly, inspection, adjustment and reassembly procedures, supported by exploded views, torque tables, service limits and wiring diagrams.

File Details

• Manual type: Motorcycle Service Manual
• Brand: Kawasaki
• Models covered: EX400GJ, EX400HJ, EX400JJ
• Engine: 4-stroke, DOHC, 2-cylinder, liquid-cooled, 399 cm³
• Language: English
• Page count: 653
• File format: PDF

Chapters Covered

• General Information — Before Servicing, Model Identification, General Specifications, Unit Conversion Table
• Periodic Maintenance — Torque and Locking Agent, Specifications, Special Tools, Periodic Maintenance Procedures (Fuel System, Cooling System, Engine Top End, Clutch, Engine Lubrication, Wheels/Tires, Final Drive, Brakes, Suspension, Steering, Electrical, Chassis)
• Fuel System (DFI) — Exploded View, DFI System, Components Naming, Parts Location, Specifications, Special Tools, Servicing Precautions, Troubleshooting, Self-Diagnosis, Sensors and Actuators
• Cooling System — Exploded View, Coolant Flow Chart, Specifications, Coolant, Water Pump, Radiator, Thermostat, Water Hoses and Pipes, Water Temperature Sensor
• Engine Top End — Exploded View, Exhaust System Identification, Specifications, Clean Air System, Cylinder Head Cover, Camshaft Chain Tensioner, Camshaft/Camshaft Chain, Cylinder Head, Valves, Cylinder/Pistons, Throttle Body Assy Holder, Muffler
• Clutch — Exploded View, Specifications, Clutch Lever and Cable, Clutch Cover, Clutch Removal/Installation
• Engine Lubrication System — Oil Flow Chart, Specifications, Engine Oil and Oil Filter, Oil Pan, Oil Screen, Oil Pressure Relief Valve, Oil Pump, Oil Pressure Measurement, Oil Pressure Switch, Oil Pipe
• Engine Removal/Installation — Removal, Installation, Swingarm Mounting Plate
• Crankshaft/Transmission — Exploded View, Specifications, Crankcase, Crankshaft and Connecting Rods, Starter Motor Clutch, Balancer, Transmission, External Shift Mechanism
• Wheels/Tires — Exploded View, Specifications, Wheels (Rims), Tires, Hub Bearing
• Final Drive — Exploded View, Specifications, Drive Chain, Sprocket, Coupling
• Brakes — Exploded View, Specifications, Brake Pedal, Calipers, Brake Pads, Master Cylinder, Brake Disc, Brake Fluid, Anti-Lock Brake System (ABS)
• Suspension — Exploded View, Specifications, Front Fork, Rear Shock Absorber, Swingarm, Tie-Rod, Rocker Arm
• Steering — Exploded View, Special Tools, Steering, Steering Stem, Handlebar
• Frame — Exploded View, Seats, Fairings, Covers, Seat Covers, Fenders, Frame, Guard, Side Stand
• Electrical System — Exploded View, Specifications, Parts Location, Wiring Diagrams, Battery, Charging System, Ignition System, Electric Starter System, Lighting System, Air Switching Valve, Radiator Fan System, Meter/Gauge/Indicator Unit, Switches and Sensors, Relay Box, Fuse
• Appendix — Cable, Wire, and Hose Routing, Troubleshooting Guide

Each chapter opens with an exploded view of the system components, followed by specifications, special tools and then the individual service procedures. Torque values appear alongside the relevant fasteners and in dedicated tables, while the periodic maintenance chapter consolidates the scheduled inspection and replacement intervals into a single chart. Whether you are adjusting valve clearance, synchronising the throttle bodies, rebuilding the clutch, servicing the front forks or tracing an ABS fault code, the manual provides the exact sequence, measurements and warnings required.

IMAGES PREVIEW

DFI Fuel Injection System

The DFI chapter is one of the most detailed sections in the Kawasaki Ninja 400 service manual, covering the complete digital fuel injection system including the ECU, throttle sensor, intake air pressure sensor, intake air temperature sensor, water temperature sensor, crankshaft sensor, gear position sensor, vehicle-down sensor, oxygen sensor, fuel injectors, fuel pump, idle speed control valve actuator and purge valve. Self-diagnosis procedures, service code tables and backup modes are all documented, alongside wiring continuity checks and component resistance values. The manual walks through fuel pressure inspection, fuel flow rate measurement, fuel hose replacement and injector fuel line leak testing with the precision a technician needs.

Engine, Transmission and Drivetrain

The EX400GJ/HJ/JJ workshop manual covers the 399 cm³ parallel-twin engine in full detail — cylinder head removal and installation, valve clearance inspection and adjustment, camshaft removal and timing, cylinder and piston inspection, piston ring wear limits, connecting rod big end bearing selection and crankshaft runout measurement. The transmission chapter includes shift drum and fork removal, shift fork bending inspection, gear dog and dog hole damage inspection, and complete drive shaft and output shaft disassembly. The clutch chapter details friction plate thickness measurement, steel plate warp inspection, clutch housing finger wear checks and release shaft service.

Chassis, Brakes and Suspension

Chassis coverage includes front and rear wheel removal, hub bearing inspection and replacement, rim runout measurement, tyre removal and installation, drive chain slack adjustment and wear inspection, engine and rear sprocket service, and coupling damper inspection. The brake chapter spans caliper disassembly, brake pad wear inspection, master cylinder rubber parts replacement, brake fluid change and bleeding, brake disc thickness and runout measurement, and the complete Anti-Lock Brake System (ABS) with hydraulic unit removal, wheel rotation sensor air gap inspection, self-diagnosis procedures and service code clearing. Front fork oil change, fork spring free length inspection, rear shock absorber removal and spring preload adjustment are all documented in the suspension chapter.

Electrical System and Wiring Diagrams

The electrical chapter provides complete wiring diagrams for both EX400G/J and EX400H models, covering the charging system, ignition system, electric starter system, lighting system, radiator fan circuit, meter unit and all switches and sensors. Battery activation, charging condition inspection, refreshing charge procedures, alternator inspection, regulator/rectifier testing, crankshaft sensor peak voltage measurement, stick coil inspection, turn signal relay testing and relay box circuit inspection are included. Component locations and connector terminal numbers are cross-referenced throughout.

Why This Manual Matters

Working on a modern fuel-injected motorcycle without the correct procedures risks expensive damage — incorrect torque on engine internals, improper DFI sensor calibration, or misdiagnosed ABS faults can all lead to costly repairs. This Kawasaki Ninja 400 repair manual gives you the exact specifications, tightening sequences, service limits and diagnostic steps that Kawasaki technicians use. The periodic maintenance chart alone is worth the investment, telling you exactly what to inspect, adjust or replace at every interval from the first service through to high-mileage maintenance.

Instant PDF Delivery

The manual is delivered as a searchable PDF that you can view on any computer, tablet or smartphone, and print the pages you need for the workshop. No shipping, no waiting — after payment you have immediate access to the complete Kawasaki Ninja 400 EX400GJ/HJ/JJ service manual. Whether you are a professional mechanic, a dedicated home wrencher or an owner who wants to understand their machine, this is the single most useful document you can have for maintaining, repairing and troubleshooting the Ninja 400.