77kz1000ltd, missing part from rear axle? (pics)

This is on my 1977 KZ1000LTD. PO had new tires put on it just before I bought it. It looks to me like something is installed wrong or left off the rear axle. I dont think its normal for the castle nut to be so deep on the axle that the cotter pin doesnt even touch it.

Also there is no mark on the chain adjuster to line up with the swing arm on the right side. Is that normal or could the chain adjuster be upside down???

It wouldnt surprise me if something is wrong here. Whoever put the wheels back on the bike after the new tires also messed up in the front. There was side to side play up front. Turns out they didnt have the speedo receiver gear engaged with the notches in the wheel hub. They left the axle nuts very loose, I'm guessing because when they tightened them up the wheel wouldnt spin because of the speedo gear problem. I got that all sorted out and now I want to make sure the rear is ok but I'm not sure what, if anything, is wrong.

From the parts diagram on Kawasaki.com, it appears that you're missing a washer that goes between the chain adjuster and the nut. (part #92022-248, WASHER,PLAIN,20MM)

Later, Doug

StreetfighterKz wrote: From the parts diagram on Kawasaki.com, it appears that you're missing a washer that goes between the chain adjuster and the nut. (part #92022-248, WASHER,PLAIN,20MM)

Later, Doug

It looks like there is a washer there but maybe its part of the adjuster? There are little dimples on it that could be spot welds? You can see two of the dimples in the third pic, one is at the top of the castle nut, the other on the left side.

I just looked at the bottom of the chain adjuster, there is an alignment mark on the bottom, inside. So I'm betting the adjuster is upside down also.

Yes to missing flat washer

Yes to flip the adjuster

That should do it.

So what looks like a washer is part of the adjuster....kinda figured that after looking at it closer.

The PO said the work (new tires) was done at a dealer. The more I learn the more I see that its by far best to get the real shop manual and do everything yourself.

My dad has a 1997 600 Eliminator, took it to the dealer for the valve check. Now its been back twice because the valve cover is leaking LOTS of oil. I told him to just get the gasket and lets do it ourself. Its just sad.

I dont trust the adjuster marks,I measure from center of swingarm pivot to center of axle bolt on each side to adjust.
Id say pull the rear wheel off and see what else is screwed up besides missing washer,not worth crashing and burning over.

I went to the local dealer to get the washer. While there a couple techs came out to look at it and they both think I'm also missing....

42032-081
COLLAR,REAR AXLE

They said it looks like the swingarm is pinched in too far. That part is obsolete so hopefully its not really missing.

Looks like I'll be pulling to check, going to change the bearings while in there too.

wireman wrote: I dont trust the adjuster marks,I measure from center of swingarm pivot to center of axle bolt on each side to adjust.

I'll be trying that trick for sure! Probably doesn't hurt to step back and eyeball it either.

74ullc wrote: I went to the local dealer to get the washer. While there a couple techs came out to look at it and they both think I'm also missing....

42032-081
COLLAR,REAR AXLE

They said it looks like the swingarm is pinched in too far. That part is obsolete so hopefully its not really missing.

Looks like I'll be pulling to check, going to change the bearings while in there too.

Post a picture of what youve got once its apart

wireman wrote: Post a picture of what youve got once its apart

I will, the hardest part of the job is going to be getting the rear end off the ground safetly. Man I wish the LTD's had a center stand.

74ullc wrote:

wireman wrote: Post a picture of what youve got once its apart

I will, the hardest part of the job is going to be getting the rear end off the ground safetly. Man I wish the LTD's had a center stand.

Lift the rear end (using a standard biker's pipe)
kzrider.com/forum/5-chassis/236039-center-stand

Parts diagram for wheel/axle assembly
kzrider.com/index.php?option=com_kunena&...w&catid=13&id=376734

Good Fortune!

Got it all apart and nothing is missing besides that washer. The collar that the mechanics at the kaw dealer thought was missing is in the brake caliper bracket.

The bearings feel good and have good fresh grease in them so I didnt change them.

The right side chain adjuster was upside down and I got that turned over so now I have a mark to go by. The rear wheel was crooked, and had the chain running in a bind. The tension on the chain (just over 1" up and down play) was correct. When I first got the rear wheel off the ground I could only spin the wheel 1/2 revolution before it would stop. Now that the wheel and chain are straight I can spin it 2 turns before it stops.

To get the rear wheel straight I went by the chain first. I got it to where its running straight when viewed from behind. Then checked the marks on the chain adjuster and then measured the distance from the center of swingarm pivot to the center of the axle bolt on each side. Everything looks spot on now, a test ride tomorrow will let me know if I got it right.

Before this the bike was wanting to lean/turn to the left. I didnt really notice it until I started to pay attention while riding over the weekend. I was pushing with my right hand to keep the bike straight without realizing it.