Drive Chain Slack Inspection
- Refer to the Drive Chain Slack Inspection in the Periodic Maintenance chapter.
Drive Chain Slack Adjustment
- Refer to the Drive Chain Slack Adjustment in the Periodic Maintenance chapter.
Wheel Alignment Inspection/Adjustment
- Refer to the Wheel Alignment Inspection in the Periodic Maintenance chapter.
Drive Chain Wear Inspection
- Refer to the Drive Chain Wear Inspection in the Periodic Maintenance chapter.
Drive Chain Lubrication
- Refer to the Drive Chain Lubrication Condition Inspection in the Periodic Maintenance chapter.
Drive Chain Removal
Note: Since the drive chain is installed through the swingarm, the chain cannot be removed other than by cutting it. Prepare the new link pin, link plate, grease seals, and tools for rejoining the chain.
Remove:
- Engine Sprocket Cover (See Engine Sprocket Removal)
- Bolts [A]
- Chain Cover [B]
![](https://motoinstruction.ru/img/kawasaki/23/128768.jpg)
- Using a suitable tool, cut the drive chain by removing the link pins.
Recommended Tool: EK Joint Tool #50
Caution: Read the Tool Manual before removing.
- Body [A]
- Handlebar [B]
- Cutting and Riveting Pin [C]
- For Cutting [D]
- For Riveting [E]
- Plate Holder (a) [F]
- Plate Holder (b) [G]
- Gauge [H]
![](https://motoinstruction.ru/img/kawasaki/23/128769.jpg)
- Grind [A] the pin head to make it flat.
- Set the cutting and riveting pin [B] as shown.
![](https://motoinstruction.ru/img/kawasaki/23/128770.jpg)
- Screw the pin holder until it touches chain pin.
- Be sure that the cutting pin hits center of chain pin.
![](https://motoinstruction.ru/img/kawasaki/23/128771.jpg)
- Screw the handlebar [A] into body.
- Turn the pin holder with wrench [B] clockwise to extract chain pin.
![](https://motoinstruction.ru/img/kawasaki/23/128772.jpg)
Drive Chain Installation
- Engage the new drive chain to the old drive chain and pull the end of the old drive chain until they are changing the position.
- Remove the old drive chain from the new drive chain.
- Apply grease to the link pins [A] and grease seals [B] [C].
- Engage the drive chain on the rear sprocket through the swingarm.
- Insert the link pins in the drive chain ends.
- Install the grease seals [C].
- Install the link plate so that the mark [D] faces out.
- Push the link plate by hand or plier to fix it.
- In case of grease seal chain, be sure to set the grease seals correctly.
![](https://motoinstruction.ru/img/kawasaki/23/128773.jpg)
- Set the plate holder (a) [A] and plate holder (b) [B] on the body.
![](https://motoinstruction.ru/img/kawasaki/23/128774.jpg)
- Fit the plate holder (a) to link plate.
- Turn the pin holder by hand until plate holder (b) touches the other link plate.
![](https://motoinstruction.ru/img/kawasaki/23/128775.jpg)
- Turn the pin holder by wrench clockwise until two pins of link come into groove of plate holder (a).
- Take off the plate holder (a).
![](https://motoinstruction.ru/img/kawasaki/23/128776.jpg)
- Set the plate holder (b) [A] and cutting and riveting pin [B] as shown.
![](https://motoinstruction.ru/img/kawasaki/23/128777.jpg)
- Turn the pin holder until riveting pin touches link pin.
![](https://motoinstruction.ru/img/kawasaki/23/128778.jpg)
- Turn the wrench clockwise until tip of riveting pin hits of link pin.
- Rivet it.
- Same work for the other link pin.
![](https://motoinstruction.ru/img/kawasaki/23/128779.jpg)
- After staking, check the staked area of the link pin for cracks.
- Measure the outside diameter [A] of the link pin and link plates width [B].
Link Pin Outside Diameter
Standard: 5.7-6.0 mm (0.22-0.24 in.)
Link Plates Outside Width
Standard: 17.25-17.45 mm (0.679-0.687 in.)
If the reading exceeds the specified length, cut and rejoin the chain again.
- Check the movement of the rollers.
- Adjust the drive chain slack after installing the chain (See Drive Chain Slack Adjustment in the Periodic Maintenance chapter).
![](https://motoinstruction.ru/img/kawasaki/23/128780.jpg)