Air Pressure Inspection/Adjustment

to the Air Pressure Inspection in the Periodic Main• Refer
tenance chapter.

Tire Inspection

to the Wheel/Tire Damage Inspection in the Peri• Refer
odic Maintenance chapter.

Tire Removal

• Remove:
Wheels (see Front/Rear Wheel Removal)
•

Valve Core (Let out the air)
To maintain wheel balance, mark the valve stem position
on the tire with chalk so that the tire can be reinstalled in
the same position.
Chalk Mark or Yellow Mark [A]
Air Valve [B]
Align [C]

the tire beads and rim flanges on both sides with
• Lubricate
a soap and water solution or rubber lubricant. This helps
the tire beads slip off the rim flanges.

NOTICE
Never lubricate with engine oil or petroleum distillates because they will deteriorate the tire.
the tire from the rim using a suitable commer• Remove
cially available tire changer.

NOTE

○The tires cannot be removed with hand tools because
they fit the rims too tightly.
Tire Installation

WARNING
Some replacement tires may adversely affect handling and cause an accident resulting in serious injury or death. To ensure proper handling and stability, use only the recommended standard tires for
replacement, inflated to the standard pressure.
the rim and tire, and replace them if necessary.
• Inspect
the sealing surfaces of the rim and tire, and smooth
• Clean
the sealing surfaces of the rim with a fine emery cloth if

•

necessary.
Remove the air valve and discard it.

NOTICE
Replace the air valve whenever the tire is replaced.
Do not reuse the air valve.

WHEELS/TIRES 10-17
Tires
a new valve [A] in the rim.
• Install
45° [B]

•
•

Front [C]
Right [D]
Apply a non-permanent locking agent to the threads of air
valve nut.
Tighten the valve nut.
Torque - Air Valve Nuts: 4.5 N·m (0.46 kgf·m, 40 in·lb)

○The air valve is as shown.
Valve
Valve
Valve
Valve

Cap [A]
Core [B]
Stem [C]
Nut [D]

the tire rotation mark on the front and rear tires and
• Check
install them on the rim accordingly.
Tire Rotation Mark [A]
Rotating Direction [B]

the tire on the rim so that the valve [A] align with
• Position
the tire balance mark [B] (the chalk mark made during

•
•
•

removal, or the yellow paint mark on a new tire).
Install the tire bead over the rim flange using a suitable
commercially available tire changer.
Lubricate the tire beads and rim flanges with a soap and
water solution or rubber lubricant to help seat the tire
beads in the sealing surfaces of the rim while inflating the
tire.
Center the rim in the tire beads, and inflate the tire with
compressed air until the tire beads seat in the sealing
surfaces.

WARNING
Overinflating a tire can cause it to explode, causing
serious injury or death. Be sure to install the valve
core whenever inflating the tire, and do not inflate
the tire to more than 400 kPa (4.0 kgf/cm², 57 psi).

10-18 WHEELS/TIRES
Tires
to see that the rim lines [A] on both sides of the tire
• Check
sidewalls are parallel with the rim flanges.
If the rim flanges and tire sidewall rim lines are not parallel,
remove the valve core.
Lubricate the rim flanges and tire beads.
Install the valve core and inflate the tire again.
After the tire beads seat in the rim flanges, check for air
leakage.
○Inflate the tire slightly above standard inflation.
○Use a soap and water solution or submerge the tire, and
check for bubbles that would indicate leakage.
Adjust the air pressure to the specified pressure (see Air
Pressure Inspection in the Periodic Maintenance chapter).
Install the air valve cap.
Adjust the wheel balance (see Balance Adjustment).

•
•
•
•
•
•

Tire Repair
Currently two types of repair for tubeless tires have come
into wide use. One type is called a temporary (external) repair which can be carried out without removing the tire from
the rim, and the other type is called permanent (internal)
repair which requires tire removal. It is generally understood that higher running durability is obtained by permanent (internal) repairs than by temporary (external) ones.
Also, permanent (internal) repairs have the advantage of
permitting a thorough examination for secondary damage
not visible from external inspection of the tire. For these
reasons, Kawasaki does not recommend temporary (external) repair. Only appropriate permanent (internal) repairs
are recommended. Repair methods may vary slightly from
make to make. Follow the repair methods indicated by the
manufacturer of the repair tools and materials so that safe
results can be obtained.

WHEELS/TIRES 10-19
Hub Bearing
Hub Bearing Removal (ZX1000R/S)

the wheels (see Front/Rear Wheel Removal),
• Remove
and take out the following.
Collars
Coupling (Out of rear hub)
Grease Seals

• Use the bearing remover to remove the hub bearings [A].
NOTICE
Do not lay the wheel on the ground with the disc
facing down. This can damage or warp the disc.
Place blocks under the wheel so that the disc does
not touch the ground.
Special Tools - Bearing Remover Head,
57001-1346
Bearing Remover Shaft,
-1377

25 ×

28 [B]:

13 [C]: 57001

Hub Bearing Installation (ZX1000R/S)

installing the hub bearings, blow any dirt or foreign
• Before
particles out of the hub with compressed air to prevent
contamination of the bearings.
Replace the bearings with new ones.

•
in each hub bearing [A] until it is bottomed.
•○Press
On the front hub, install the left bearing firstly.
○On the rear hub, install the right bearing firstly.

Special Tool - Bearing Driver Set [B]: 57001-1129

NOTE

○Use the bearing driver set which does not contact the
bearing inner race.
○Install the bearings so that the marked side faces out.
the grease seals with new ones.
• Replace
Press
in
the grease seals [A] so that the seal surface is
• flush [B] with
the end of the hole.

○Apply high-temperature grease to the grease seal lips.
Special Tool - Bearing Driver Set [C]: 57001-1129

Hub Bearing Inspection
Since the hub bearings are made to extremely close tolerances, the clearance can not normally be measured.

NOTE

○Do not remove any bearings for inspection. If any bearings are removed, they will need to be replaced with
new ones.

10-20 WHEELS/TIRES
Hub Bearing
each bearing in the hub back and forth [A] while
• Turn
checking for plays, roughness, or binding.

•

If 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.

Hub Bearing Lubrication
NOTE

○Since the hub bearings are packed with grease and
sealed, lubrication is not required.

FINAL DRIVE 11-1

Final Drive
Table of Contents
Exploded View .......................................................................................................................
Specifications ........................................................................................................................
Special Tools ..........................................................................................................................
Drive Chain.............................................................................................................................
Drive Chain Slack Inspection ............................................................................................
Drive Chain Slack Adjustment ..........................................................................................
Wheel Alignment Inspection/Adjustment ..........................................................................
Drive Chain Wear Inspection ............................................................................................
Drive Chain Lubrication.....................................................................................................
Drive Chain Guide Wear Inspection..................................................................................
Drive Chain Removal/Installation......................................................................................
Sprocket, Coupling .................................................................................................................
Engine Sprocket Removal ................................................................................................
Engine Sprocket Installation .............................................................................................
Rear Sprocket Removal....................................................................................................
Rear Sprocket Installation.................................................................................................
Coupling Installation..........................................................................................................
Coupling Bearing Removal ...............................................................................................
Coupling Bearing Installation ............................................................................................
Coupling Bearing Inspection .............................................................................................
Coupling Bearing Lubrication............................................................................................
Coupling Damper Inspection.............................................................................................
Sprocket Wear Inspection.................................................................................................
Rear Sprocket Warp Inspection ........................................................................................

11-2
11-4
11-5
11-6
11-6
11-6
11-6
11-6
11-6
11-6
11-6
11-10
11-10
11-10
11-11
11-11
11-12
11-12
11-13
11-13
11-13
11-13
11-14
11-14

11

11-2 FINAL DRIVE
Exploded View

FINAL DRIVE 11-3
Exploded View
No.
1
2
3
4
5
6

Fastener
Engine Sprocket Cover Bolts
Engine Sprocket Nut
Rear Axle Nut
Rear Sprocket Nuts
Chain Guide Mounting Bolt
Chain Cover Mounting Bolts

N·m
10
147
130
60
1.8
3.0

Torque
kgf·m
1.0
15.0
13.3
6.1
0.18
0.31

ft·lb
89 in·lb
108
95.9
44
16 in·lb
27 in·lb

HG: Apply high-temperature grease.
HO: Apply heavy oil.
L: Apply a non-permanent locking agent.
MO: Apply molybdenum disulfide oil solution.
(mixture of the engine oil and molybdenum disulfide grease in a weight ratio 10:1)
R: Replacement Parts
S: Follow the specified tightening sequence.

Remarks

MO
R, S
L
L

11-4 FINAL DRIVE
Specifications
Item
Drive Chain
Drive Chain Slack
Drive Chain Wear (20-link Length)
Standard Chain:
Make
Type
Link
Sprockets
Rear Sprocket Warp

Standard

Service Limit

25  35 mm (1.0  1.4 in.)
317.5  318.2 mm (12.50  12.53 in.)

– – –
319 mm (12.6 in.)

ENUMA
EK525RMX3/3D
114 links
TIR 0.4 mm (0.016 in.) or less

– – –
– – –
– – –
TIR 0.5 mm (0.020 in.)

FINAL DRIVE 11-5
Special Tools
Inside Circlip Pliers:
57001-143

Bearing Driver Set:
57001-1129

11-6 FINAL DRIVE
Drive Chain
Drive Chain Slack Inspection

to the Drive Chain Slack Inspection in the Periodic
• Refer
Maintenance chapter.

Drive Chain Slack Adjustment

to the Drive Chain Slack Adjustment in the Periodic
• Refer
Maintenance chapter.

Wheel Alignment Inspection/Adjustment

to the Wheel Alignment Inspection in the Periodic
• Refer
Maintenance chapter.

Drive Chain Wear Inspection

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

Drive Chain Lubrication

to the Drive Chain Lubrication Condition Inspection
• Refer
in the Periodic Maintenance chapter.

Drive Chain Guide Wear Inspection

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

Drive Chain Removal/Installation
NOTE

○The drive chain is installed through the swingarm. So
as to remove the chain, it has to cut.
○Prepare the new link pin, link plate, grease seals, and
tools for rejoining the chain.

• Remove:
Left Front Footpeg Bracket Bolts [A]
Left Front Footpeg Bracket [B]

• Remove:
Chain Cover Mounting Bolts [A] and Washers
Chain Cover [B]

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

FINAL DRIVE 11-7
Drive Chain
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]

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

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

the handlebar [A] into the body.
• Screw
the pin holder with the wrench [B] clockwise to ex• Turn
tract the link pin.

the link pin, link plate and grease seals.
• Replace
Apply
grease
to the link pins [A] and grease seals [B] [C].
• Engage the drive
on the engine and rear sprockets.
• Insert the link pinschain
in
the
• Install the grease seals. drive chain ends.
• 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.
•

11-8 FINAL DRIVE
Drive Chain
the plate holder (A) [A] and plate holder (B) [B] on the
• Set
body.

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

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

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

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

FINAL DRIVE 11-9
Drive Chain
the wrench clockwise until the tip of riveting pin hits
• Turn
of the link pin.
it.
• Rivet
Same
work for the other link pin.
•

staking, check the staked area of the link pin for
• After
cracks.
the outside diameter [A] of the link pin and link
• Measure
plates width [B].
Link Pin Outside Diameter
Standard: 5.6  6.0 mm (0.22  0.24 in.)
Link Plate Outside Width
Standard: 19.15  19.30 mm (0.7539  0.7598 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).

a non-permanent locking agent to the chain cover
• Apply
mounting bolts [A].
the chain cover [B] and washers.
• Install
• Tighten:
Torque - Chain Cover Mounting Bolts: 3.0 N·m (0.31 kgf·m,
27 in·lb)

the left front footpeg bracket.
• Install
Tighten:
•
Torque - Front Footpeg Bracket Bolts: 25 N·m (2.5 kgf·m,
18 ft·lb)

11-10 FINAL DRIVE
Sprocket, Coupling
Engine Sprocket Removal

• Remove:
Engine Sprocket Cover Bolts [A]
Engine Sprocket Cover [B]

out the bended washer [A].
• Flatten
Remove
the engine sprocket nut [B] and washer.
•

NOTE

○When loosening the engine sprocket nut, hold the rear
brake on.