rear axle missing a washer?

I've got a '77 KZ400-D4. I replaced the tires, and after assembly, I notice that the rear axle protrudes so far that the cotter pin doesn't engage the castle nut. Seems a bit off, as if there should be an extra washer under the head of the rear axle bolt.

right castle nut:

i.imgur.com/dl0uoND.png


left head of axle:

i.imgur.com/vTvrOo7.png

It's a thick washer and yes it's missing.
Steve

Thanks, SWest. There should be a washer maybe 1.5mm thick, outside the frame and right under the castle nut? I see one in the parts fiche, Kawi part 42046-009. I have what looks like a washer painted or welded onto the chain tension adjuster yoke, but it's less than 1mm thick. I thought maybe that was washer 42046-009. Guess not.

If it's supposed to go outside the frame, it's not a big issue, I can just get something at the hardware store. But if I'm missing a washer inside the frame, then it would throw my rear wheel's left/right alignment off.

Looks like the spacer on the chain side is backwards. The clean side should face in. Does the wheel spin freely when it is tightened?
Steve

SEE: www.kawasaki.com/Parts/PartsDiagram/142746/1977/KZ400-D4 . Then use the part number (42046-009 ) to find a replacement sleeve washer on eBay or elsewhere.

Ed

> Looks like the spacer on the chain side is backwards. The clean side should face in.

Do you mean the "nut coupling" just needs to be flipped over, or that it goes to the wheel-side of the chain adjuster? I'm guessing you mean the latter. That would dish the rear wheel like 4mm to the right, and would make a huge difference in alignment!

Also, on the chain side, the thickness of washer 92022-293 is important for alignment. I don't trust that this bike came with correct parts, so if anyone can find the thickness spec of that washer, I can doublecheck mine. The description is "24mm plain washer" so I'm guessing 25mm x 40mm x 4mm

I notice that the right side chain adjuster is mounted incorrectly. The raised part that looks like a washer should be inside the swingarm and face the wheel not the outside of the swingarm. Ed

They are double sided but only one side will have the notch facing up. They are right or left.
The spacer on the chain side is clean suggesting it was facing in past the seal. I should be installed in the same position.
Steve

Thanks, SWest and 650ed! Sounds like I need to swap the chain adjusters between left and right sides, so that the reinforced side is inside facing the wheel; and the adjustment notches face up. And I need to add the 3.7mm-thick washer on the right side, which should fix the cotter pin issue.

I looked on YouTube, and found videos showing axle mounted left to right; or right to left. Some had the "nut coupling" on the left side under the axle head; others under the castlenut on left; others with no nut coupling visible (either not there, or mounted inside the adjusters).

I have a manual labelled "74-77 KZ400 searchable full manual" which shows the axle inserted from the left side, through the Coupler Nut, then through the chain adjuster. The diagram shows washer #23 between Coupler Nut and Collar, but it doesn't show if that washer goes outside of the chain adjuster, or to the wheel side. I'm guessing it's 4mm thick, so putting it inside vs outside the chain adjuster would affect alignment.

Pic of my 77 kz1000 axle with washer, chain side. Looks like you may just need the missing washer ?