Kawasaki ER 5 / KLE 500 / GPZ 500 / EX 500 - Engine REBUILD - Part 12 Output shaft assembly

[@cryptomasterbehemoth6655]

Couldn't help but notice that O-ring still sitting there when you were done putting it together.

[@dirtygarageguy]

Just gone over the video again, lol the o ring goes on between the spacer coller and the bearing, which is coming up soon. Basically it goes on when the sprocket does, which is where I'm up to now.

[@metalflesh1]

He is going balls deep.

[@arunasjunevicius533]

Oh you're cracking me up Matt. Great vid mate

[@dirtygarageguy]

Which bit?

[@AaronWolfenbarger]

My cams turn fine until I torque the head bolts in then they lock up. I dont have the chain attached to it so there is no engine movement and they turn freely you know until the lobes hit the lifters but it wont budge at all when I torque the head down. The guy at teh machine shop said it wasnt cracked, it isnt warped and it pressure tested fine so whats causing this to happen?

[@dirtygarageguy]

Are you trying to turn this by hand or with a wrench?

[@AaronWolfenbarger]

@@dirtygarageguy well with the head just sitting on it but the head bolts ( not the cam cap bolts) not tightened I can turn it with my hand until it hits a cam lobe then it stops on the lifter but when I tighten the head bolts down its like its warping and the cam caps lock onto the cams. The machine shop said it wasnt warped or cracked so I dont know wth is going on. someone in the forums said it could be the locator dowl pins so I bought new ones and am waiting for them.

[@warwiener]

I am sorry to say this but think you put warsher and clip in wrong order at 7:58 dog gear either floats free or rides against the next gear and diverts pressure to opposite side to free wheeling gear. also part picture says order is wrong link to picture static.motorcyclespareparts.eu/images/kawasaki/motorcycles/CE_99_1.JPG Ps. Sorry for my bäd english i am from Finland and keep doing these amazing videos,

[@mariusm5187]

yeah the weather was just unbearable :D

[@dirtygarageguy]

You're not kidding I died twice!

[@kawarider9049]

Wrong order of washer and circlip. And also when putting 3th and 4th gear (order of mount), you put that “tube” (the tube is on shaft and wheels on this tube) wrong, there are oil holes in that tube and you need to fit them with shaft.

[@dirtygarageguy]

Caught this at the time dude - but thanks a lot - matt

[@kawarider9049]

The Workshop thanks for reply bro ;) how is it now? Does the ER5 works fine? I finished the transmission gear wheels change today, transmission did noise at 4th and 6th gear and I am a little bit scared from that clips. Bought the new ones (they are so fking expensive) because the old ones looked like they are too “free” and they were rotating easily. Mounted the new ones and they are rotating too, not so easilly, you have to push them a little bit, but I am not very happy from that.. so i’d like to know if it’s OK, I saw that yours were rotating probably like mine new ones

[@dirtygarageguy]

The clips take axial loading and not radial load so as long as they don't snap then they should be fine.

[@kawarider9049]

The Workshop so its no problem if they turn later?

[@dirtygarageguy]

no - in a nut shell