1981 KZ1000 CSR M1 - Front Sprocket Removal

I have done this job a couple of times, but the nut was in decent shape, so I used a socket and large breakover bar. I used an extension for the breakover bar, to gain some clearance from the engine. Then placed a cinder block + a piece of 3/4" wood beneath the bar to support it while carefully standing and jumping on the bar. To hold the sprocket from turning, I put the bike in gear and had a helper to hold down the rear brake.

The second time I did the job, I could not get the nut loose. (Some goose (me) must have over tightened the nut. Wound up grinding the nut away in two places, to a point just above the threads, so that it fractured and came loose with a socket.

I tried some heat, but worried about ruining a seal inside the transmission. I would think also that hammering on the nut might damage the bearings inside as well. This is a tough job, and young children or grandmothers should try to do it. Hell, grown men have a difficult time with it - as evidenced by this discussion.

I believe his bike uses a bolt rather than a nut, so cutting it off isn't an option. If nothing will grab the bolt firmly enough to loosen it welding a nut to it may be the next best solution. Ed

maybe there is a washer that splines in with the sprocket, it would be bent over the side of one of the flat parts of the nut.

you are going to need a breaker bar and a socket with someone to stand on the brakes.

There are several washers and lock plates but they have all been removed, and having somebody stand on the brake does help a lot, which I have also done. And as far as an update on removing the sprocket BOLT...it is completely and udderly rounded now. I bought that craftsment set I mentioned earlier and it still will not come off no matter how much torque I put on it. Is this bolt a counterclockwise to remove like normal? Or is it the opposite of whats normal? Thanks for the help, this job sucks.

get a good set of vise grips and some leverage. I used the handle of my 3 ton floor jack on the end of a ratchet I think it was 1 1/16". Or you could get a new nut and use a dremel cut off wheel to get the old one off as a last resort, you may have to cut into the threads of the sprocket shaft. there is always the option of a pickup truck and a trip to the machine shop.

Judging by the parts diagram there's no nut to cut on the KZ1000-M1. It has a bolt holding the sprocket on. Ed

z1wiz wrote: ...hold a much larger nut that fits completely over the bolt head in place and weld inside the nut to the bolt. Now you can easily put a socket on the nut and hit it with the impact to remove....

If the rounded bolt head is accessible to a small pipe wrench, such wrench grips tighter as more pressure is applied. Failing that, would weld on a nut per z1wiz's suggestion.

Fingers crossed that the bolt head doesn't snap off leaving the shank embedded inside the shaft.

Good Fortune!

I have a set of bolt/nut extractors from craftsman, i used them yesterday works great.

www.sears.com/shc/s/p_10153_12605_009520...pncode=35-32697294-2