Wrong sprocket or issue with output shaft?

The output shaft splines on my 78 KZ1000 B2 do not extend past the outboard side of the front sprocket for the lock washer to secure to.

The splines on the output shaft extend to about 7.5 mm from the case and the sprocket is a little more than 8mm thick in the center. Should the splines come out farther? Do I have the wrong sprocket? I don't have the correct service manual yet but searching around it looks like I might have a later model sprocket on there.

I have tried flipping the sprocket around so that the circular indentations are facing outboard but that does nothing to help the lock washer problem and moves the sprocket inboard a little bit. I think the previous owner might have tried that because there is a scar where a chain has rubbed the case.

Not that you asked, but that sprocket looks badly worn out. Time for a new one.

According to JT Sprockets your front sprocket should measure 10mm thick at the splined hole. You may want to measure.

www.jtsprockets.com/catalogue/model/5529

I recently changed my front sprocket on my KZ1000A2 and the splines do not come all the way through the sprocket, that's so the nut can tighten the sprocket without binding on the splines. however what is different is that my lock washer is a plain washer to fit over the thread not the splined shaft. I think you have the wrong washer on there and that's why it's confusing.

I checked my old sprocket and it's 10.17mm thick so I'm confused as to how yours is only 8mm thick. The stock sprocket has a small boss bout 1.5mmor so deep on the back of it, are you including that in your 8mm measurement?

79-80 he has the right washer. However, as was stated before that sprocket is worn out, get a new sprocket, front and rear and a new chain before that things breaks going down the highway

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floivanus wrote: 79-80 he has the right washer. However, as was stated before that sprocket is worn out, get a new sprocket, front and rear and a new chain before that things breaks going down the highway

His bike's a 78, the same as mine, how is it the right washer if it doesn't fit the shaft? i.e. there are no splines for it to fit over. Depending on how it was fitted, it might not be locking the nut in place either.

I'm sure this is the washer he should have:







Item #35, Part Number 92024- 044

Sprocket is wrong, or there is a shim behind it. My money is on wrong. Oe style has a recess in the middle so that washer can fit on the very end of the splines.

But yes, wrong sprocket for that locking tab. Your tab can be used, but sprocket needs to be addressed

The washer I included a picture of, is the correct washer for his 1978 bike, from the Kawasaki parts manual for a 1978, if the OP got the right washer all the perceived problems would go away, although I agree he needs a new front sprocket as well. I don't understand why you are insisting it's the right washer and wrong sprocket, when it's the right sprocket and the wrong washer that's the case here for a 1978 KZ1000B2.

The output shaft for a 79 is a different part number and the lock washer is part # 92200-1065 for a 79 and it has the teeth to match the splines of the shaft as opposed to being a plain washer like 94024-044 on the 77-78 bikes, The sprocket is the same part number for 78 and 79, so for the washer with spline cut outs to fit the output shaft of the 79+ bikes, there must be a longer splined area on the shaft to allow for the width of the washer. I suspect the modification was made to the output shaft and washer so the sprocket would be able to completely sit with it's full width on the splines for extra strength and durability. The plain washer setup on 77 and 78 KZ1000's is a carry over form the Z!'s which used the same set up to secure the front sprocket - it wasn't changed until the 79 model year.

Only difference in the output shaft is the row of teeth that mesh with the input is slightly wider. I had a pile of trannies last year.

Yes the washer you pointed out is correct, for that year, i was wrong. BUT, like I said, he needs to buy two new sprockets and a chain first. The 530 set i bought from Z1E, for example, uses neither sprocket nut retaining setup. Best best; chain, sprockets, retainer as a package

The 530 sets from Z!E use the KZ650 front sprockets, if I remember correctly so are set up for yet another type of retainer, the sort with spline cut outs but that rotates out of position in a cutout in the splines, and is held with 2 6mm bolts to keep the sprocket from coming off.

I still think the splines on the 79 and up KZ1000 output shaft will have about 2mm more spline length than the 77-78 so everything can fit on to the splines, unless the shaft can somehow be moved over to compensate. Mine is exactly like JohnnyMoffs, the splines do not quite go through the entire sprocket width, probably 1 mm or so short. With my new 530 sprocket from Z1E and their 1,5mm spacer behind to give the same width (10mmm), and spacing as the original it was exactly the same fit on the splines.

Thanks everyone! This makes total sense to me now. I will get new sprockets, chain and washer right away.

Don't feel bad about being confused, I thought my set up was strange when I first took it apart because of the splines not coming through the sprocket, I had a double take, almost thought something was broken on the shaft, I quickly realized it wasn't, but had someone slipped the incorrect washer in there, like you had, I would have been certain something was seriously wrong.

Yep, the situation renders the splined washer ineffective as a lock washer.

For the correct washer am I correct in thinking that the little tab goes into the hole on the sprocket and then you bend the washer up against the nut?