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Old 06-20-2014, 11:30 PM   #1
MikeGayner OP
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Am I crazy? Replacing bent-tab washers with star-lock + Loctite

I'm slowly putting the motor of my Kawasaki A7 back together and today did the gearbox. When I removed the shift forks they used lock-tab washers on the pins:


These weren't re-usable, and I was going to struggle to get replacement washers without paying silly money. So instead I replaced them with internal star style locking washers (of the same thickness as the bent tab washers) and some blue Loctite.





I'm new to all this, and although I'm 99% sure I've done a perfectly acceptable thing, I could do with a bit of reassurance. What do you think?

Thanks.

http://a7avenger.wordpress.com/2014/...ox-reassembly/
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Old 06-20-2014, 11:49 PM   #2
JeffS77
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I could be totally wrong but would a wave/spring washer work better in the application ?

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Old 06-21-2014, 10:28 AM   #3
anotherguy
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The vibration and heat made the engineer spec the locking tab washer. Don't second guess when the cost of failure is so high.
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Old 06-21-2014, 10:57 AM   #4
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The vibration and heat made the engineer spec the locking tab washer. Don't second guess when the cost of failure is so high.
yeah, that's risky business you have going on there.. make the washers out of thin steel/tin/brass/sheet metal/whatever you need to. the mechanical lock tabs are there for vibration. easier to make some lock tab washers out of sheet metal then to replace everything one of the bolts will tear up when it decides to back out.
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Old 06-21-2014, 09:22 PM   #5
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I wouldn't do it either, the cost of them will be worth the peace of mind and you won't have to tear it apart for more expensive repairs later.

Also red locktite is more preminant than blue if you are stuck on not going with the locking tabs.
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Old 06-21-2014, 11:58 PM   #6
rgmax
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Just did this on my H2. The part is readily available through any Kawasaski dealer, part number 92031-001, about $4 each.

This isn't something you want to revisit. Spend the money, you'll sleep better.
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Old 06-22-2014, 03:51 AM   #7
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Just did this on my H2. The part is readily available through any Kawasaski dealer, part number 92031-001, about $4 each.

This isn't something you want to revisit. Spend the money, you'll sleep better.
Won't be available in New Zealand without paying ridiculous shipping costs.
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Old 06-22-2014, 10:14 AM   #8
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What if I pick a few up and toss 'em in an envelope? Will you be charged stupid import taxes or something? I'm more than willing to risk the $ to help you do it right. What's the part number?
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Old 06-22-2014, 02:16 PM   #9
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What if I pick a few up and toss 'em in an envelope? Will you be charged stupid import taxes or something? I'm more than willing to risk the $ to help you do it right. What's the part number?
No there won't be any import taxes, the problem is overseas suppliers always ship using ordinary air shipping with no flexibility. It's incredibly hard to get parts here without paying huge shipping costs. E.g., this is what it looks like if I try to order the washers from Partzilla:



If you're willing to do that for me I'd be happy to pay a reasonable price. The part number is 92031-001. If you're able to get them to me for a reasonable cost I'd be quite prepared to pay you for your time. Shipping them in an envelope would incur ordinary letter rates, e.g. a few bucks. Unfortunately none of the US or UK parts suppliers are interested in doing anything other than looking up a rate in their UPS charts.
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Old 06-22-2014, 02:22 PM   #10
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You sure live in a nice spot on the island.
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Old 06-22-2014, 02:35 PM   #11
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It's expensive living in paradise, what can I say. It's the middle of winter here and ideal riding weather today. Can't complain too much.
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Old 06-22-2014, 04:39 PM   #12
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Yeah I'll do that. I'll shoot you a PM when I get 'em in my hands. I'll run by the local dealer tomorrow. He's got a good parts dept. and should have 'em in stock.
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Old 06-22-2014, 05:16 PM   #13
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You're a good man, cheers.
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Old 06-23-2014, 09:11 AM   #14
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He doesn't have them in stock so I had to order. Be about a week.
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Old 06-23-2014, 02:19 PM   #15
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It's great to have a forum full of such awesome people. Thanks a lot anotherguy
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