What's wrong with this picture? (Z1 Brake Pedal)

Hey Guys,

I'm a bit stumped. This is a photo of a customer's Z1 brake pedal. The 8mm nut on the pedal assembly is correct OEM and is supposed to be identical to the footrest assembly mount nuts also pictured (which are not OEM).

There are the required flatwasher and spring (lock) washer already installed but the dome nut is bottoming out as pictured. Schematics (which are known to be occasionally inaccurate)dont' show any more spacers behind the pedal assembly and spring, for that matter, the schematics dont' even show the stud the assembly fits on, but I strongly suspect something is missing behind the pedal.

Z1 brake pedals can be a bit of a process to remove and inspect so before I advise him to do so I wanted to see if it looks familiar to anyone.

Thoughts?

isnt it supposed to have one of those thick washers with the rolled edges and then the lock washer and nut?not for sure :huh: .

leon

Well, according to the fiche diagram, it appears to be complete. The flat washer is described/reported as 1.6mm thick accoridng to Kawasaki.

Next!

You are missing spacers and the large flange washer. It is clearly shown in the manual. That diagram is not showing everything.

Just sent you a PM. I'm looking at a factory service manual. Not seeing what you are apparenlty.

I will try to get to my storage area today and take a picture of it. I will post it.

Otakar,
I assume the spacer (thick rolled-edge washer) config yo're referencing is on the inner side of the pedal? Where does the return spring fit into the equation?
I guess a picture WILL be worth the proverbial 1,000.

Thanks in advance.

I see the Z1 uses the exact same combo of washers and nuts that a KZ650 does so just to compare the way it's set up is:
The pedal presses onto the knurled part of shaft up til its flush with the frame, no spacers. At this point the knurled part of the shaft should be completely covered by the pedal and only the threaded stud should be sticking out. Measuring with a ruler the stud is about 10mm long. On this stud goes the 1.6mm flat washer and a 1.5mm approx lockwasher so the remaining stud is now 6.9mm give or take. The nut measures about 13mm in total length on the outside and is threaded on so the 13mm is more than enough to cover a 6.9mm stud.
Hopefully this will help.

Problem solved!:laugh:

RonK's post above prompted a more thorough inspection of just what was happening. Seems there was some buggered threads on the cap nut.

A little more persuasion caused proper seating against the assembly! :woohoo:

Thanks to all!