Z1OwnersClub GB

I wonder if I might prey upon your members intimate knowledge of Zeds to help with a problem I'm having whilst building up a friends bike. I'm sure it's a Z1b and the P Redg would tally quite nicely with that theory.

When I came to refit the rear wheel I have a lot of space left over on the axle, around 10mm!
I have checked the diagrams and all spacers, washers, etc are present, so now I have started measuring things to see where this extra gap comes from.

Does anyone have a Zed in bits at the moment or even just the parts and is able to wave a ruler over some of them?

These are what I get:

Wheel(brake plate, sprocket and spacer fitted)183mm
sprocket side spacer (as above) 10mm
brake side spacer 33mm
Axle(inside edge of head to start of thread) 263mm

swing arm forks (inside edge) 230mm
swing arm forks (outside edge) 257mm
I suppose that the width of the forks is irrelevant as they will pinch in when tightened but the fact that they are much wider than the wheel assembly is suspicious, as on all my triples the wheel plus spacers are a tight fit into the forks especially with the adjusters fitted.

given that the overall width of all the Zed parts (inc adjusters) comes to 251mm and the thread on the Axle stops at 263mm, you can bet it's loose!!

Also, where does the brake lamp fail relay mount? The connector appears from the loom under the rear of the tank, but I can't see any obvious bolt around there to nail the bracket to.


Any help greatly appreciated

Gra.




(Edited by Wolfman at 9:26 pm on May 22, 2006)


(Edited by Wolfman at 8:28 pm on May 23, 2006)

Wolfe,
Wheel(brake plate, sprocket and spacer fitted)183mm (Not measured yet)
sprocket side spacer ....10mm OK.
brake side spacer .....33mm OK.
Axle(inside of head to start of thread).....263mm OK.

swing arm forks (inside edge)....230mm OK

swing arm forks (outside edge).....257mm (make it 258+)
Thickness of chain adjuster ....4.5mm (each side)
Washer under castlelated nut... 2mm.
Width to check pull-up (swing-arm) 258 + 4.5 + 4.5 + 2 = 269mm. Which looks OK, with regards to length of bolt .
However, we could have something incorrect regarding the small (approx 40 mm) bearing holder and spacer, that fits in the sprocket holder. I have seen the incorrect spacer there!. I realise the problem is not yet solved.

The brake-outage unit is mounted off the LHS coil mount. It is a sheetmetal "L" shaped piece that locks under one of the coil mounting bolts. The Brake-outage unit has a rubberised sleeve around it that is slotted, so that it can be slid to fit in the sheetmetal mount. It is easily made and I dare say someone will have a photo, let's know if you you need one.
RegardZ

Hello Garn

Many thanks for the reply and help, all the things measured so far are ok, as you say, which leaves the wheel/sprocket/brake assembly as I measured these as one lump.

I have just been back to the garage, ruler in hand... no jokes here please!

Even before ruling things again, I had a closer look, the rear wheel hub and brakeplate are both clean and nicely polished, the sprocket carrier however, is well unpolished and the sprocket itself is almost rusty under all the oil, sort of not in keeping with the rest of the wheel assy.. I wonder?

So, I have now sat the carrier on the floor, sprocket upwards and 10mm spacer fitted, then measured down the Axle hole (please!) this measures around 82-83mm to the ground, is that something that you can check?

Thanks for the info on the relay mounting, I can go and fit that later, I have the bracket and re zinced it the other day cos it was a rusty mess, but when I picked the bike up the relay was just sat on the LH Cyl head behind the plug with no clues as to it's location, then when I replaced the harness, the connector for it became evident.

I hope you get to ride yours more than we do ours, the weather is lousy and has been for weeks over here, have fun.

Wolfie, that measurement of the sprocket-holder, from the spacer to the ground is the same as from the alloy nmachined surface of the sprocket-holder to the ground. It is as you said 82mm.
I think your trouble is in that little spacer, that fits into the bearing that mounts in the sprocket-holder.
It is 42 mm long and the part that fits in the bearing is 15 mm. There is a shoulder approx 5mm and the rest of it acts as the distance spacer to keep the fins of the sprocket-holder that support the shock rubbers, from rubbing on the hub. If the spacer is not what I have stated you probably have one from a 650 or something. I had this troiuble last year.

I have a few hubs in various states of assembly.

RegardZ.
PS. I'm thinking that, maybe that sprocket holder could be off a 650!
Measure the diameter of the sprocket boss. They are snmaller in diameter than the 900, however, they look identical at a glance!....

Hello Garn

Thanks for the info again, I had an email from the owner this morning, the sprocket carrier bearing had been replaced a while back but otherwise everything should be original....

However, looking at the parts diagrams, they all show a carrier with a centre that stands out way above the level of the sprocket, the one I have here is only just higher than the sprocket.

http://www.kawasaki.org.uk/saved/sprocket_assy.jpg
http://www.kawasaki.org.uk/saved/carrier.jpg
[url=http://www.kawasaki.org.uk/saved/axle.jpg

The]http://www.kawasaki.org.uk/saved/axle.jpg

The[/url] carrier spacer is around 42mm and any longer would make the carrier stand off the hub , leaving a gap to view the cush drive through, or move the carriers bearing and seal outwards, the seal would have to be external!
By the boss, I think you mean this centre bit that sticks through the centre of the sprocket, this is about 95mm dia.

I did notice that the hub bearing for the sprocket side is sunk into the wheel by about 10mm, whereas the brake side bearing is flush, but I can't see that this would affect the overall width as if it were further out, the above problems would arise again!

The owner is busy at the moment but I am going to call over next week with the bits to compare against some 900A4 bits he has laying around.

My favourite culprit for today is the sprocket carrier being too short, as I say, the carriers condition is not in keeping with the rest of the wheel, who knows...

Thanks once again.




(Edited by Wolfman at 10:42 pm on May 25, 2006)