Kawasaki Z1000SX - Service manual > Drive Chain

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

• Remove:
  Mud Guard (see Mud Guard Removal in the Frame chapter)
  Rear Wheel (see Rear Wheel Removal in the Wheels/Tires chapter)
  Chain Cover Bolt [A]

• Remove:
  Clamp [A]
  Chain Cover [B]
  Swingarm (see Swingarm Removal in the Suspension chapter)

• Remove:
  Engine Sprocket Cover (see Engine Sprocket Cover)
• Remove the drive chain [A] from the engine sprocket [B], and take it off the chassis.

Drive Chain Installation

• Install the drive chain to the engine sprocket.
• Install:
  Swingarm (see Swingarm Installation in the Suspension chapter)
  Rear Wheel (see Rear Wheel Installation in the Wheels/Tires chapter)
  Engine Sprocket Cover (see Engine Sprocket Cover Installation)
• Insert the projection [A] on the chain cover into the swingarm hole [B].
• Adjust the drive chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).

Drive Chain Replacement

• Remove:
  Chain Cover (see Drive Chain Removal)
  Engine Sprocket Cover (see Engine Sprocket Removal)

NOTICE For safety, if the drive chain shall be replaced, replace it using a recommended tool.

Recommended Tool -
 Type: EK Joint Tool #50
 Brand: ENUMA

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]

• Grind [A] the pin head to make it flat.
• Set the cutting and riveting pin [B] as shown in the figure.

• Screw the pin holder until it touches chain pin.
• Be sure that the cutting pin hits center of chain pin.

• Screw the handlebar [A] into body.
• Turn the pin holder with wrench [B] clockwise to extract chain pin.

• Replace the link pin, link plate and grease seals.
• Apply grease to the link pins [A] and grease seals [B] [C].
• Engage the drive chain on the engine and rear sprockets.
• Insert the link pins in the drive chain ends.
• Install the grease seals.
• Install the link plate [D] so that the mark faces out.
• Push the link plate by hand or plier to fix it.
• In case of grease seals chain, be sure to set the grease seals correctly

• Set the plate holder (A) [A] and plate holder (B) [B] on the body.

• Fit the plate holder (A) [A] to link plate.
• Turn the pin holder by hand until plate holder (B) [B] touches the other link plate.

• Turn the pin holder [A] by wrench clockwise until two pins of link come into groove of plate holders [B].
• Take off the plate holder.

• Set the plate holder (B) [A] and cutting and riveting pin [B] as shown in the figure.

• Turn the pin holder until riveting pin touches link pin.

• Turn the wrench clockwise until tip of riveting pin hits to the link pin.
• Rivet it.
• Same work for the other link pin.

• 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: 5.6 - 6.0 mm (0.22 - 0.24 in.)

Link Plates Outside Width
 Standard: 20.35 - 20.55 mm (0.8012 - 0.8091 in.)

If the reading exceeds the specified length, cut and rejoin the chain again.

• Check: Movement of the Rollers
• Adjust the drive chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).

See also: