Output shaft nut fell off!

I was just about 5 miles from home returning on a 160 mile ride, when my brake light kicked on, it sounded like my chain broke, and suddenly I had no power. I pulled over in a parking lot and my chain was really loose. Luckily my dad could come pick me up with the trailer, and as soon as I got home I tore the side cover that houses the front sprocket. The output shaft nut and lock washer were both sitting on the bottom of the cover in some grease (leaky output shaft seal). My sprocket worked its way off the splines, thus why it couldn't move anywhere. The lock washer looked toast, so it failed to do its job.

Has this ever happened to anyone before? I'm thinking of using loctite on it after I change out the leaky output shaft seal, but don't know if I should get another original lock washer or try something different. Any suggestions? And how hard is it changing the output shaft seal? I imagine its a bit of a job.

You mean like this.... YUP!

I learned, the hard way of course :blush: , to use Blue locktite when installing it back on... Also, insure the washer tab isn't broken off for this is what occurred in my case. Torques for 104 ft pounds....

It's happened to me 3 or 4 times over the years. If you have the proper lockwasher setup it won't happen. It happens from trying to reuse the washer and the tang breaks off or using aftermarket sprockets that don't have the hole for the washer. Most aftermarket do not have the hole, so shop around and insist on a decent sprocket.

Use red thread locker and it will never come off under stress, even without the locking tabs or anything. You dont have to over do it, just a nice thin bead around 4-5 threads of the bolt/nut.

When time for removal, an impact wrench works fine with a little twist of the socket with your hand, no biggie.

Changing the output shaft seal is a piece o' cake if I remember correctly. You just pry the old one out, then grease the new one, and use a hollow pvc pipe/dowel to evenly rubber mallet the new one in.

GL.

Yes, mine have come off twice due to re-using tabbed washers.

But red loctite will assure that you will need a torch to heat the nut up, 6 foot pipe for the large socket and two teenage boys to hold the bike down as you put everything you have onto the end of said pipe. I wish I had an impact wrench that day. :laugh:

I would just use a new tabbed washer and maybe some blue loctite.

my sprocket doesnt have a hole. i just use blue loctite and a cheap electric, impact gun.

i use red and hammer it on and off with an impact in fact i haven't had a washer in place for years don't waste my time or money with such things last time i had one fall off was around 5 years ago on my street bike. and the only reason it fell off was i couldn't find my loctite when i did a sprocket and chain change buy your self a cheap electric impact if you don't have an air one. i have a cordless18 volt that i use at the track and works fine

Wow,sounds more common that I thought! Turns out my lock washer actually fits the splines and doesn't have an arm that fits into the sprocket. I snapped some pictures of everything before I cleaned it up.

The nut and washer. Only one or two tabs are bent on it.


This is where they were sitting.


Greasy mess


My chain has some scuff marks now too.


A little damage here.


Not sure if I will reuse this washer or not. I don't see why I couldn't, since it fits the splines. I will use some loctite for sure for cheap insurance. I'm going to clean everything up nice and replace that seal for sure.

Thats some nasty lookin sh-- right there.bj

toadson wrote:

...Not sure if I will reuse this washer or not. I don't see why I couldn't, since it fits the splines....

kawasaki.com shows the special washer is still available, part no. 92200-1065, used on a host of various models.

Good Fortune!

Yep...it's happened to me too a few times,but I have spares now.

what kind of chain lube do you use,if you use chain wax or something light like it you wont end up with that kind of mess under the cover.