RonKZ650 wrote: ...... Problem is the worm passages get clogged with old grease almost right away then you can pump all day through the zerk and no grease goes anywhere. ......

I've never had that problem with mine and I've had the bike for 39 years, but I lube the swing arm every 1,000 miles. Grease always flows freely through the worm passages. on mine. I guess if it is neglected the grease could coagulate, but I have no idea how long that would take. One thing I would say is that the worm passages on the original swing arm sleeves are more widely spaced and are more laterally oriented than I have seen on some replacement sleeves (see images below), so that may have an effect. To me, the replacement sleeves look like they could clog up easier than the originals. Ed

ORIGINAL SLEEVE


REPLACEMENT SLEEVE

The design of the bushing setup with the sleeve was pretty poor, so I don't blame anyone for wanting to get rid of the bushings for needle bearings. The way the grease zerk works on the 1977 model with the bushings is grease goes in through the zerk, then travels several inches via worm passages in the sleeve to the bushings. This is the concept anyway. Problem is the worm passages get clogged with old grease almost right away then you can pump all day through the zerk and no grease goes anywhere. Good reason they got rid of that system quickly, one of the worst designs ever.

If the owner is so dopey that he doesn't know the swingarm has a grease fitting maybe you should hardtail the swingarm and tell him it is permanently lubed. :laugh: :laugh: :laugh: Ed

Thanks for the advice. If this was my bike, I would, at minimum, swap the arm for a uni-track and have twin shock mounts welded on, or go with a single shock set up. Something other than messing with the worn out parts I have to work with now!

But this is a "customer's" bike that I'm resurrecting from a storage and maintenance neglect nightmare. You guys have to see what kind of rectifier this bike has on it! I'll post some pictures later in the projects section. The original swing arm bushings and center sleeve were so worn that the rear wheel has about 1/4" of sideways movement. While the bushings are still available, the sleeve is obsolete unless you can find a NOS one (they are out there, but are generally over $100 on evil-bay).

Given the fact that bushings generally wear faster than bearings, and for how much it would cost to replace all the stock parts, I would like to put bearings in. Oh - the owner wasn't even aware there is a grease fitting on the swing arm, so I won't expect regular maintenance to be done...yeah, bearings will likely be wiser on this one...

Assuming the D4 axle is the same diameter as the 650-CSR & using the 650-csr for comparison.

The 1000-CSR has a larger rear axle, so the caliper, swing arm adjusters & the various wheel spacers etc will have a larger ID, and they may be larger overall, so using the D4 stuff may not be feasible. The 1000-csr shares some rear wheel stuff with a few other 1000 models. I would get a couple of spacers from a 1000 to see how they compare to the D4, such as the 42036-1039 sleeve & 92027-1287 collar.

The 1000-csr has the same spokes & rims & the same large sprocket carrier bearing as the 650-csr, so the sprocket carrier & hub are probably sized basically the same as the 650. The sprocket carrier side has some other stuff that's the same. There may be bearings that will mate the 1000-csr stuff to a 650-csr or D4 axle. again, assuming the D4 stuff is the same size as the 650-csr.

TheBaron wrote: Hey,

I have found a set of wire spoke wheels from an Australian 1978 Z1000. The front wheel is a twin disc 19" a4 wheel, and the rear is a disc with an 18" rim., standard fit to that model bike. Seems like the ones I'm looking for, if anyone can tell me from their experiences whether these will work out.

Conghos, I'm in Australia, I thought that was the only place the Z650D4 was delivered. When you say there is " no direct replacement with any zed bikes" what exactly do you mean? Will this never work with spoke rims with this D4 swing arm and forks or does this setup just need minimal modification and spacers made up. What about the standard D4 brake calipers, would that possibly work.I don't mind the mags, just want to do a wire wheel bike and a full fairing.

Cheers.

Baron, thanks for the compliment. Loads of D4 bikes here in Argentina but we lack spare parts. What I meant with direct swap was that you take the mags and place the spoked one, "plug and play". Ie: the GS425 cames with mags -EN versión- or spokes wheels -N versión-, Either if you like mags or spoked wheels you can just take out them and place the others, you use the same calipers, rotors, axle, etc. With the D4 is more complicated, not imposible, but worth the effort? In my case I was looking for a 18" front wheel and there is a z police that use it but it's a 4 bolt mag wheel, then I have a lot of parts to change.

I guessed that you were in Australia, someday I will visit your country...!

Let me know if I can help you with something else. Cheers.

Hey,

I have found a set of wire spoke wheels from an Australian 1978 Z1000. The front wheel is a twin disc 19" a4 wheel, and the rear is a disc with an 18" rim., standard fit to that model bike. Seems like the ones I'm looking for, if anyone can tell me from their experiences whether these will work out.

Conghos, I'm in Australia, I thought that was the only place the Z650D4 was delivered. When you say there is " no direct replacement with any zed bikes" what exactly do you mean? Will this never work with spoke rims with this D4 swing arm and forks or does this setup just need minimal modification and spacers made up. What about the standard D4 brake calipers, would that possibly work.I don't mind the mags, just want to do a wire wheel bike and a full fairing.

Cheers.

What about installing a 750E swingarm? You can get one for cheap on ebay.

Why bother? The bushings work great as long as you lube them on a regular basis. Ed

Hey, any of you early (77-78) KZ650 owners know of a way to replace the OEM bronze swing arm bushings with roller needle bearings (without spending hundreds of $$$$ ?

Does the Z1 / KZ900 kit offered by Z1 ent. fit the KZ650?

Thanks!