Engine Sprocket Removal
Remove:
- Engine Sprocket Cover Bolts [A]
- Engine Sprocket Cover [B]
![](https://motoinstruction.ru/img/kawasaki/23/128781.jpg)
Remove:
- Speed Sensor Bracket Bolts [A]
- Speed Sensor Bracket [B]
![](https://motoinstruction.ru/img/kawasaki/23/128782.jpg)
- Flatten out the bended washer [A].
- Remove the engine sprocket nut [B] and washer.
Note: When loosening the engine sprocket nut, hold the rear brake on.
![](https://motoinstruction.ru/img/kawasaki/23/128783.jpg)
- Raise the rear wheel off the ground with stand.
- Loosen the drive chain (See Drive Chain Slack Adjustment in the Periodic Maintenance chapter).
- Remove the drive chain from the rear sprocket toward the right.
- Pull the engine sprocket [A] with drive chain [B] off the output shaft [C].
- Disengage the drive chain from the engine sprocket.
![](https://motoinstruction.ru/img/kawasaki/23/128784.jpg)
Engine Sprocket Installation
- Replace the sprocket washer with a new one.
- Install the engine sprocket [A] so that "OUT SIDE" letters [B] face outward.
- Apply molybdenum disulfide oil solution to the threads of the output shaft and seating surface of the engine sprocket nut.
Tighten:
Torque - Engine Sprocket Nut: 125 Nm (12.7 kgf·m 92 ft·lb)
![](https://motoinstruction.ru/img/kawasaki/23/128785.jpg)
Note: Tighten the engine sprocket nut while applying the rear brake.
- After tightening the engine sprocket nut, bend [C] the one side of the washer over the nut.
- Be sure that the dowel pins [D] are in position.
Tighten:
Torque - Speed Sensor Bracket Bolts: 9.8 Nm (1.0 kgf·m 87 in·lb)
- Install the engine sprocket cover, and tighten the bolts securely.
- Adjust the drive chain slack after installing the sprocket (See Drive Chain Slack Adjustment in the Periodic Maintenance chapter).
Rear Sprocket Removal
- Remove the rear wheel (See Rear Wheel Removal in the Wheels/Tires chapter).
Caution: Do not lay the wheel on the ground with the disc facing down. This can damage or warp the disc. Place wooden blocks under the wheel so that the disc does not touch the ground.
- Remove the rear sprocket nuts [A].
- Remove the rear sprocket [B].
![](https://motoinstruction.ru/img/kawasaki/23/128786.jpg)
Rear Sprocket Installation
- Install the sprocket facing the tooth number marking [A] outward.
- Tighten the rear sprocket nuts.
Torque - Rear Sprocket Nuts: 59 Nm (6.0 kgf·m 44 ft·lb)
- Install the rear wheel (See Rear Wheel Installation in the Wheels/Tires chapter).
![](https://motoinstruction.ru/img/kawasaki/23/128787.jpg)
Coupling Installation
- Apply high-temperature grease to the coupling grease seal lips [A].
- Apply grease to the coupling internal surface [B].
![](https://motoinstruction.ru/img/kawasaki/23/128788.jpg)
Apply grease to the new O-ring [A]. Install the collar [B].
![](https://motoinstruction.ru/img/kawasaki/23/128789.jpg)
Coupling Bearing Removal
Remove:
- Coupling
- Grease Seal
- Circlip [A]
Special Tool - Inside Circlip Pliers: 57001-143
![](https://motoinstruction.ru/img/kawasaki/23/128790.jpg)
- Remove the bearing [A] by tapping from the wheel side.
Special Tool - Bearing Driver Set [B]: 57001-1129
![](https://motoinstruction.ru/img/kawasaki/23/128791.jpg)
Coupling Bearing Installation
- Replace the bearing with a new one.
- Press in the bearing [A] until it is bottomed.
Special Tool - Bearing Driver Set [B]: 57001-1129
- Replace the circlip with a new one.
Special Tool - Inside Circlip Pliers: 57001-143
![](https://motoinstruction.ru/img/kawasaki/23/128792.jpg)
- Replace the grease seal with a new one.
- Press in the grease seal so that the seal surface is flush with the end of the hole.
Apply high-temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set: 57001-1129
Coupling Bearing Inspection
Since the coupling bearing is made to extremely close tolerances, the clearance can not normally be measured.
Note: It is not necessary to remove the coupling bearing for inspection. If the bearing is removed, it will need to be replaced with a new one.
![](https://motoinstruction.ru/img/kawasaki/23/128793.jpg)
- Turn the bearing in the coupling back and forth [A] while checking for plays, roughness or binding.
If the bearing play, roughness or binding is found, replace the bearing.
- Examine the bearing seal [B] for tears or leakage.
If the seal is torn or is leaking, replace the bearing.
Coupling Bearing Lubrication
Note: Since the coupling bearing is packed with grease and sealed, lubrication is not required.
Coupling Damper Inspection
- Remove the rear wheel coupling, and inspect the rubber dampers [A].
- Replace the damper if it appears damaged or deteriorated.
![](https://motoinstruction.ru/img/kawasaki/23/128794.jpg)
Sprocket Wear Inspection
- Visually inspect the engine and rear sprocket teeth for wear and damage.
If the teeth are worn as illustrated, replace the sprocket, and inspect the drive chain wear (See Drive Chain Wear Inspection in the Periodic Maintenance chapter).
- Worn Tooth (Engine Sprocket) [A]
- Worn Tooth (Rear Sprocket) [B]
- Direction of Rotation [C]
![](https://motoinstruction.ru/img/kawasaki/23/128795.jpg)
Note: If a sprocket requires replacement, the chain is probably worn also. When replacing a sprocket, inspect the chain.
Rear Sprocket Warp Inspection
- Raise the rear wheel off the ground with stand so that it will turn freely.
- Set a dial gauge [A] against the rear sprocket [B] near the teeth as shown, and rotate [C] the rear wheel to measure the sprocket runout (warp). The difference between the highest and lowest dial gauge readings is the amount of runout (warp).
If the runout exceeds the service limit, replace the rear sprocket.
Rear Sprocket Warp
Standard: 0.4 mm (0.016 in.) or less
Service Limit: 0.5 mm (0.020 in.)
![](https://motoinstruction.ru/img/kawasaki/23/128796.jpg)