Kawasaki Z400 - Service manual > TisRod, Rocker Ann

Tie-Rod Removal

• Squeeze the brake lever slowly and hold it with a band [A]
• Remove: Muffler Cover (see Muffler Removal in the Engine Top End Chapter)

• Loosen: Upper Tie- Rod Nut [A] Lower Tie-Rod Nut [B] Lower Rear Shock Absorber Nut [C] Rocker Arm Nut [D]
• Support the frame using the suitable stand
• Remove: Upper Tie-Rod Nut and Bolt Lower Rear Shock Absorber Nut and Bolt Rocker Arm Nut and Bolt
• Remove: Lower Tie-Rod Nut [A] and Bolt [B] Tie- Rods [C] Rocker Arm [D]

Tie-Rod Installation

• Apply grease to the inside of the oil seals
• Replace the following nuts with new ones.

  Tie-Rod Nuts Rocker Arm Nut Lower Rear Shock Absorber Nut

• Install the tie-rods so that the marked side [A] faces outside and rocker arm side.
• Install the lower tie-rod bolt and nut
• Install the rocker arm so that the marked side [B] faces front right side.
• Tighten the bolts and nuts following the specified

Tie-Rod and Rocker Ann Bearing Removal

• Remove: Swingarm Mounting Plate [A] (see Engine Removal in the Engine Removal/Installation chapter) Rear Shock Absorber (see Rear Shocker Absorber Removal) Rocker Arm [B] (see Tie-Rod Removal) Sleeves [C] Oil Seals [D]
• Remove the needle beatings [E] using a suitable tool.

Tie-Rod and Rocker Arm Bearing Installation

•  Replace the needle bearing and oil seals with new ones.
• Install the needle bearings

The installing positions are as shown.

Special Tool - Bearing Driver Set: 57001 412

• Apply plenty of grease to the lips of the oil seals.
• Install the oil seals.

Viewed from Bottom [A]

Swingarm Mounting Plate [B]

Grease Seals [C]

Needle Bearings [D]

Rocker Am [E]

Te-Rods [F]

Rear Shod< Absorber [G]

5.5 M.5 mm (0.22 M.02 in.) [H]

16.8 k0.5 mm (0.66 a.02 in.) [I]

Rocker Arm/Tie-Rod Bearing, Sleeve Inspection

NOTICE

Do not remove the bearings for inspection. Removal may damage them.

Visually inspect the rocker arm, sleeves [A] and needle bearings [B].

The rollers in a needle bearing normally wear very little, and wear is difficult to measure. Instead of measuring, inspect the bearing for abrasion, color change, or other damage.

*If there is any doubt as to the condition of any of the needle bearings or sleeve, replace the sleeve and needle bearings as a set.

Rocker Arm/Tie-Rod Bearing Lubrication

NOTE

Since the bearings are packed with grease, lubrication is not required.

See also: