Brake cam lever - "grrrrr"

The '81 KZ0B that I recently acquired came with no front brake cable or lever, and with the forward cam lever hanging loose. After cleaning the mechanism I'm ready to reassemble the wheel, but now despair of ever reattaching the darn cam lever. The inner jaw falls right in place, but the outer jaw will not seat. I can't find a fault in the teeth on either the lever or the cam, see no way to spread the outer jaw (with any kind of wedge that I own) and have come to actually consider buying a fully assembled brake plate just to avoid the issue. If there's a trick to this, I never learned it.

I'm not optimistic about a solution to this simple problem, but appreciative of the chance to vent. Ain't it always the little things that cause the most frustration?

If helpful for reference, here's a diagram from kawasaki.com.

[Click on image to enhance view]



Good Luck!

Oh, I have the manual. I think that who ever removed this thing must have tweaked it out of parallel when they levered it out.

mwriders wrote:

...forward cam lever hanging loose...despair of ever reattaching the darn cam lever...inner jaw...outer jaw...teeth on either the lever or the cam, see no way to spread the outer jaw (with any kind of wedge that I own)....

Here's the parts list from kawasaki.com.

Am uncertain of exactly which parts are damaged and nature of the damage. And not comprehending why whatever's bent can't be straightened.:S

Perhaps posting a photo of the damaged part(s) would be helpful toward diagnosis.

Good Luck!


[Add checked items to Pick-List] REF NUMBER PART NUMBER DESCRIPTION QUANTITY US CA CN REMARKS
[View Supersession]
[Add to Picklist: 112G0618]
110 112G0618 BOLT-UPSET 1
[View Supersession]
[Add to Picklist: 112G0630]
110A 112G0630 BOLT-UPSET 2
[View Supersession]
[Add to Picklist: 311B0500]
311 311B0500 NUT,5MM 1
[View Supersession]
[Add to Picklist: 410B1400]
410 410B1400 WASHER PLAIN 14MM 1
[View Supersession]
[Add to Picklist: 411B0600]
411 411B0600 WASHER PLAIN 6MM 1
[View Supersession]
[Add to Picklist: 550D1210]
550 550D1210 PIN COTTER 1.2X10 2
[View Supersession]
[Add to Picklist: 550D3025]
550A 550D3025 PIN COTTER 3.0X25 1
[Add to Picklist: 610B6302]
601 610B6302 UNAVAILABLE IN PRICE BOOK 1
[View Supersession]
[Add to Picklist: 601B6302Z]
601A 601B6302Z BEARING BALL #6302Z 1
[Add to Picklist: 41034-1008]
41034 41034-1008 DRUM-ASSY,FR BRK 1
[Add to Picklist: 41035-1005]
41035 41035-1005 PANEL-ASY,FR BRK 1
[View Supersession]
[Add to Picklist: 41048-019]
41048 41048-019 SHOE,BRAKE 2
[Add to Picklist: 41050-016]
41050 41050-016 CAM SHAFT,FRONT BRAKE 2
[View Supersession]
[Add to Picklist: 41053-011]
41053 41053-011 LEVER FRT BRK CAM 1ST 1
[View Supersession]
[Add to Picklist: 41053-012]
41053A 41053-012 LEVER FRT BRK CAM 2ND 1
[View Supersession]
[Add to Picklist: 41058-008]
41058 41058-008 ROD END,BRK CONNECT 1
[View Supersession]
[Add to Picklist: 41058-009]
41058A 41058-009 ROD END,BRK CONNECT 1
[View Supersession]
[Add to Picklist: 41060-007]
41060 41060-007 PINION SPEEDOMETER 1
[Add to Picklist: 41060-1014]
41060A 41060-1014 GEAR,SPEEDOMETER,30T 1
[Add to Picklist: 41068-045]
41068 41068-045 AXLE,FRONT 1
[Add to Picklist: 41085-015]
41085 41085-015 INDICATOR,FR BK SHOE 1
[Add to Picklist: 41057-004]
43011 41057-004 ROD BRK CAM LEV CONCT 1
[Add to Picklist: 41072-007]
92015 41072-007 NUT,6MM 2
[View Supersession]
[Add to Picklist: 42045-020]
92015A 42045-020 NUT,14MM 1
[Add to Picklist: 41052-005]
92022 41052-005 WASHER,BRAKE CAMSHAFT 1
[View Supersession]
[Add to Picklist: 41063-003]
92022A 41063-003 WASHER PINION THRUST 2
[View Supersession]
[Add to Picklist: 41039-011]
92027 41039-011 SPACER F AXLE BEARING 1
[Add to Picklist: 92027-1049]
92027A 92027-1049 COLLAR,FRONT AXLE 1
[View Supersession]
[Add to Picklist: 41062-003]
92028 41062-003 BUSH SPEDMETER PINION 1
[View Supersession]
[Add to Picklist: 41055-003]
92043 41055-003 PIN BRAKE CONNECT ROD 2
[View Supersession]
[Add to Picklist: 92050-017]
92049 92050-017 OIL SEAL WOC55687 1
[View Supersession]
[Add to Picklist: 92052-005]
92049A 92052-005 OIL SEAL WTC25428 1
[View Supersession]
[Add to Picklist: 41049-004]
92081 41049-004 SPRING FRNT BRK SHOE 2
[View Supersession]
[Add to Picklist: 41056-001]
92081A 41056-001 SPRING FR BRK CAM LEV 1
[Add to Picklist: 41051-001]
92093 41051-001 DUST SHIELD BRAKE CAM 2