Boxes of basket case

I am putting together a bike from boxes of stuff and my plan is to assemble the bike the way I want it to look then tear it down, cut off whatever tabs I don't want, paint and reassemble. I started with taking "D" parts and putting them on an "H" frame and discovered that's not gonna work. Everything I have with the exception of an extra frame and motor is from a "D".

I took the wheels to a shop and got the bearings replaced and new rubber. Today, when I was trying to fit the tail back together the rear wheel assembly would not fit between the swing arm forks...WTFO? I'm thinking I don't have something together quite right. I have been using a Clymer manual and referring to the Kawasaki parts diagrams online but I haven't been able to locate the diagrams for a D yet.

Anybody got a solution to this problem? Here are some pics....

Anybody know what this little fella is and where on the bike it goes?

Looks like a front axle spacer. Nice looking rims.
Steve

My guess is what steve said, but I'll add that it goes just inside that chrome cover, which I believe also goes on the front wheel? Correct me if I'm wrong

I haven't been able to locate the diagrams for a D yet.

D models are shown as SR on the Kawasaki parts site.

Because you are fitting a 650D model rear wheel in an H model frame, the spacers are probably wrong.
Compare the diagrams of the D & H models, and find the differences.

This post has D model diagrams, and some info on the

forums.kz650.info/index.php?topic=14866.0
D rear wheel:

Here's an H rear:

Hard to compare the parts above, as the part numbers are not shown, but the spacer on the far right when looking from the rear (next to the axle in the dia.), #14 in the D diagram, and #92027 in the H diagram, look to different in shape and size.

52 Tele wrote:

Attachment image-5.jpeg not found

At least one culprit is that chrome cover, it does not belong on the rear wheel, it sits on the right side of the front wheel.

I took the wheels and parts that looked like they should be attached to the wheels to a shop for tires and bearing replacement. They did in fact put the front hub dust covers on the rear wheel. There's a flat dust cover and the dome dust cover and bothe were stacked on the right side of the rear hub. I removed them and, viola, it fits! It' missing a spacer or something though cuz there is open space between the brake caliper housing axle attachment and the bearings. Thanx to rstnick for pointing out the SR on the kawi parts diagrams! I should be able to verify all the parts thru that.

Thanx. I have boxes of D and H parts that are all jumbled together. I do have dual discs up front on the wheel I'll use. I took the forks to a shop for service and seal replacement. I read a horror story about tackling that oneself without the right tools and decided it better to avoid throwing stuff and kicking the dog so I caved on that... I should get those and a new rear sprocket in a week or so and then I'll put the front together and see what I got...

52 Tele wrote: Anybody know what this little fella is and where on the bike it goes?

Attachment image-7.jpeg not found

From the side it looks like a piston for a brake caliper! Is it solid? Or a hole thru it?

OnkelB wrote:

52 Tele wrote:

Attachment image-5.jpeg not found

At least one culprit is that chrome cover, it does not belong on the rear wheel, it sits on the right side of the front wheel.

Good catch!
I saw that picture, and didn't even notice.
:laugh: