Kawasaki Z400 - 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 in the Periodic Maintenance chapter.

Drive Chain Guide Wear Inspection

• Refer to the Chain Guide Wear Inspection in the Periodic Maintenance chapter.

Drive Chain Removal

• Remove: Swingarm (see Swingarm Removal in the Suspension chapter)
• 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 the removed parts (see appropriate chapters).
• Adjust the drive chain slack after installing the chain (see Drive Chain Slack Adjustment in the Periodic Maintenance chapter).

Drive Chain Replacement

• Remove: Mud Guard (see Mud Guard Removal in the Frame chapter) 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 fiat.
• Set the cutting and riveting pin [B] as shown.

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

• Screw the handlebar [A] into the body.
• Turn the pin holder with the wrench [B] clockwise to extract the link 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 so that the mark [D] faces out.
• Push the link plate by hand or plier to fix it.
• 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) to the link plate.
• Turn the pin holder by hand until the plate holder (B) touches the other link plate.

• Turn the pin holder by a wrench clockwise until two pins of link come into groove of the plate holder (A).
• Take off the plate holder.

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

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

• Turn the wrench clockwise until the tip of riveting pin hits of 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: 5.3 - 5.7 mm (0.21 - 0.22 in.)

Link plates outside width Standard: 17.35 - 17.50 mm (0.6831 - 0.6890 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).
• Install the removed parts (see appropriate chapters).

See also: