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Z 200 clutch assembly 18 Jan 2023 20:15 #878976

  • jphempstead@gmail.com
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Hello there, I am look for a needle in a haystack? Well kinda… I bought my partner a kz 200 1981. I’ve been rebuilding the engine due to previous neglect. I have stumbled across a problem whilst re assembling the clutch. In the diagram, number 17 is a particular washer. I do not have this washer and can’t remember if it ever existed on the tear down… but coincidentally every Kawasaki dealer I have tried says it’s been discontinued. What to do? Re assemble without washer? Or pull what little hair I have left out?
I hope that this falls on some wise ears! 
thank you in advance.
joe 
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Z 200 clutch assembly 19 Jan 2023 08:34 #878991

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I didn't see the 1981 KZ200 on the CMSNL site, so I looked at the 1979 Canadian KZ200. The diagram appears to be the same [as the one you posted] and I'm taking a guess that there will not be any differences between that model and the 1981.

Thankfully part number 17 is just a plain washer so you have some leeway as far as a replacement, but the Kawasaki part number (from CMSNL) is 92022-321. Searching ebay for the part number and Kawasaki reveals this item:

Kawasaki 92022-321 WASHER, PLAIN NOS NEW xs8250
https://www.[ebay].com/itm/133536668726
1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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Last edit: by Nerdy. Reason: Fix formatting

Z 200 clutch assembly 20 Jan 2023 06:48 #879051

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I wonder why a thrust washer isn't used there?  

Just an fyi, #18 is listed as a plain washer in the clutch diagram, but when you click the part, it's listed as a thrust washer.  

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Z 200 clutch assembly 20 Jan 2023 08:29 #879055

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Not sure why that would be, but #17 is listed as a plain washer:

1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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Z 200 clutch assembly 20 Jan 2023 19:03 #879089

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Hiya nerdy, I too could only find the 1979 kz or kl diagrams online. Im assuming they are the same. Although in my 1977 onwards Haynes  manual it has a few drawings with crank assembly which differ, ie kick start pinion and other thrust washers. But mainly all identical. My 1981 z200 only has electric start. 
so number 17 says plain washer but in my manual says it’s a thrust washer,17 and 18 not plain…
Every source I have tried says out of stock or discontinued… I
appreciate your link but the last three numbers don’t match, part 17 ends in 321 and the link washer is 231, very close but not exact.
would Kawasaki answer a question in a email possibly? 
thank you for helping me out, much appreciated.

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Z 200 clutch assembly 20 Jan 2023 19:07 #879090

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It says both are thrust washers in my Haynes manual. I do have number 18 but confused about 17. It says on re assembly it is a large thrust washer… I thought I was meticulous about keeping everything together and labelling everything, plus I took photos of everything and can see large washer anywhere… I’m verging on thinking it was not used on that year model…??? 

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Z 200 clutch assembly 21 Jan 2023 09:05 #879115

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The KZ250s don't show #17 between the hub & housing; and the part numbers for the hub & housing are different than the 79 200 (although the 200 is showing 2 hub part numbers, one of which is the same as the 250). Maybe yours is the same as the 250?   EB pics can be handy for comparing stuff.  ps: various other makes & models are showing either a plain washer, thrust washer or collar/spacer.

edit: the 79-82 Z250/KZ305 FSM is showing #17 as a thrust washer for the 79 250 (#11 on pg 63 in the FSM). I'm not seeing an exploded diagram for the later models and don't have a 200 manual.

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Z 200 clutch assembly 21 Jan 2023 10:51 #879120

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Not sure if this will be of any help or not bu t from the Kawasaki.com site they list a 1981 CSR which appears to be a single so I think it is a 200/250 and it's clutch info does not show said washer (thrust or plain.
 

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1977 KZ650 B1
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