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My apologies to DiamondSkyBlue1000, I really didn’t intend to highjack your thread….did you figure out what is going on?

Not sure what happened there either
Been working late every night this week and haven't gotten to it yet.

Hi, old thread indeed, l've got the dreaded rear wheel binding up after doing rear wheel bearing replacement on KZ1000A1, l've done this before on other model Zeds with no problems, got me beat, everything appears to be refitted correctly but when l tighten up axle nut it locks up solid (no brake pads in caliper or chain fitted), loosen wheel and spins fine, did you ever get to bottom of your problem? i'm about to knock bearings out too check width of new bearings l've just fitted
, thanks

Check the spacer positions. 
Steve

Thanks Steve, have done that, all good there, l'm thinking replacement bearings are out of spec too originals that came out, but l didn't think to check before fitting, bugga , another 39 bucks

The bearings should not be out of spec, they are all std sizes. The only thing i can think of is you assembled the hub in he wrong order. The circlip is on the Disc side and is the first to come out and last to refit. Refit the collar with the flange facing the sprocket side before the disc side bearing is fitted. i use the spindle to allgn this spacer at various stages of drifting in the sprocket side bearing. Make sure that the bottom bearing holes in the hub are not burred or damaged in any way. If some one has tried to drift out the disc side bearing without removing the circlip you could end up with major damage. I always have drifted the disc side in JUST enough for the circlip to fit. Verify you can just move the collar to one side as the bearing is drifed in the last few mm


Same story for the sprocket carrier hub bearing, it collar can only go in one way.

Have you done anything further on this D-3?

Rick H.