axle block/chain adjuster questions - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
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post #1 of 19 (permalink) Old 10-16-2019, 12:22 PM Thread Starter
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axle block/chain adjuster questions

The bolts and nuts on my chain adjusters are looking tired. One's slightly bent. The threads are flattened in places. The nuts are rounded. They still work but I'm trying to get the bike overall in better condition, avoid potential problems.

I removed one today, thinking it would be a simple matter of replacing the old bolts with new, but then realized something I have not notice before. The axle block and bolt seem to be one piece (?). I don't get it. Seems like it would have been easy to make a block with an exchangeable bolt. Or am I missing something?

I looked for aftermarket replacement blocks/bolts, and found zero that fit. I realize there are some used ones out there for our bike but the ones I have seen pictured don't look a heck of a lot better than mine. So I'm probably going to try to straighten the bolt, use a thread file on them, find some new nuts for them. I have already had trouble finding two different sized nuts that fit that bolt at the hardware store.

Question one, before I do this, does anyone know of an aftermarket replacement?

Question two, is there problem with using the same sized nuts on the bolts (other than it would require me to carry two wrenches of the same size in the tool kit)? I even considered using something like a wing nut on the outer bolt, but worried that might get knocked loose somehow.

If any of you have any pointers/experience with this, love to hear from you.

Thanks.
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post #2 of 19 (permalink) Old 10-16-2019, 4:14 PM
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Question #1: Not as far as I know but they can be gotten new for about $25. (Kawasaki part # 33040-1116)

Question #2: Not a problem, other than the inconvenience you mentioned. The thread size is 8X1.25mm. Once the axle is properly torqued, the adjusters are just along for the ride, so anything that doesn't fall off will do the job. I got tired of the double nutting and replaced the 2 nuts with a single nyloc on each side which worked fine. Don't trust the index marks. They were accurate on my EX but others have reported the marks to be way off on their bikes.
post #3 of 19 (permalink) Old 10-16-2019, 6:12 PM Thread Starter
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Thanks so much. I will probably just order a couple of new ones. And I will think about the nylocs option too. I do not trust the index marks. I usually measure from center of swing arm bolt to center of axle. That said I'm thinking of getting a chain alignment tool of some kind. I know this string thing is best but I have yet to master that.
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post #4 of 19 (permalink) Old 10-16-2019, 10:18 PM
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mine were poor on the gen 2 [gen 1's are different] fixed mine in about an hour. remove blocks hold in vice cut off the threads flush with block drill out the old bolts slide in new high tensile bolts with the heads cut off weld in place fit to bike with single nylock shouldered nut. job done.
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post #5 of 19 (permalink) Old 10-17-2019, 9:24 AM Thread Starter
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Yorkie, alas, I lack both tools and skills. But thank you for the idea. You've given one more reason I should learn to weld, and get a welder, and mount a vice....
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post #6 of 19 (permalink) Old 10-17-2019, 9:48 AM
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I have a set of gen 1 on my work bench if you want them let me know in a pm.

1993 Teal/White EX500 6K First Street Bike
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post #7 of 19 (permalink) Old 10-17-2019, 10:05 AM
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The String Thing

You can read, just by a ball of mason chord and doo the string thing. You'll love yourself in the mourning.'Be sure to do the Rocking of the forks first and the vertical phase last

FOG

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post #8 of 19 (permalink) Old 10-17-2019, 10:08 AM Thread Starter
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Kevin, thank you, I have the 2nd generation though.

Fog, I'll give it another shot with a clearer head. Thanks.
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post #9 of 19 (permalink) Old 10-17-2019, 3:48 PM Thread Starter
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I was able to straighten the bent bolt. May try an inexpensive tap and die set and see if I can freshen up the threads.
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post #10 of 19 (permalink) Old 10-17-2019, 4:05 PM
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I keep on e of thease in the tool bag.

https://www.amazon.com/Motion-Pro-08...s%2C125&sr=8-4

1993 Teal/White EX500 6K First Street Bike
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post #11 of 19 (permalink) Old 10-17-2019, 11:37 PM
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The Ninja 250 and 300, the KLE300/Versys 300, and ER-500 swingarm chain adjusters are all the same as the ones used on the 2nd gen 500 swingarm. You will have better luck finding a nice used set since they're newer, or as mentioned above, new ones are still available for $17.54.

'90 EX-5R w/ 2nd gen forks, Fox shock, aftermarket Ninja 250 wheels, 04 GSXR tail, undertail exhaust w/ Harley mufflers.

Last edited by willi777; 10-18-2019 at 12:12 AM.
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post #12 of 19 (permalink) Old 10-18-2019, 2:19 AM
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Quote:
Originally Posted by yorkie View Post
mine were poor on the gen 2 [gen 1's are different] fixed mine in about an hour. remove blocks hold in vice cut off the threads flush with block drill out the old bolts slide in new high tensile bolts with the heads cut off weld in place fit to bike with single nylock shouldered nut. job done.
Aren't blocks aluminium and bolt steel
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post #13 of 19 (permalink) Old 10-18-2019, 6:02 PM
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Aren't blocks aluminium and bolt steel
mine were steel blocks it's how I damaged the threads trying to get them out they rusted in solid. perhaps they were non standard if the OEM's are alloy. or is it that mines a European model. Dunno. sorry for the confusion if this is the case.
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post #14 of 19 (permalink) Old 10-18-2019, 6:25 PM Thread Starter
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Yorkie, this is a different topic but I was wondering if you could tell me more about the standard chains you use. I read on another threat that you used them, and tried sending you a message through this site but not sure if it worked. I'd be interested in hearing about the brands you use, how often you have to tighten them, how long they are lasting for you. Would greatly appreciate any info you can give me about them. Thanks!
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post #15 of 19 (permalink) Old 10-18-2019, 9:43 PM
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yes it did, PM sent. will answer more tomorrow evening.
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post #16 of 19 (permalink) Old 10-19-2019, 9:20 AM Thread Starter
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Thanks!
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post #17 of 19 (permalink) Old 10-19-2019, 4:02 PM
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Quote:
Originally Posted by yorkie View Post
mine were steel blocks it's how I damaged the threads trying to get them out they rusted in solid. perhaps they were non standard if the OEM's are alloy. or is it that mines a European model. Dunno. sorry for the confusion if this is the case.
Ah, I had hoped you've stumbled upon Ferrari's patented "ferran" process for welding steel to aluminium. Could use some of that tech. I suppose it's some sort of brazing with filler metal that sticks to both. Perhaps copper, silicon & zinc blend...
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post #18 of 19 (permalink) Old 10-19-2019, 5:40 PM
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Originally Posted by willi777 View Post
The Ninja 250 and 300, the KLE300/Versys 300, and ER-500 swingarm chain adjusters are all the same as the ones used on the 2nd gen 500 swingarm. You will have better luck finding a nice used set since they're newer, or as mentioned above, new ones are still available for $17.54.
If this is the case, Amazon has some trick alloy adjusters that would do what you want for little money. Some of them even have trick lift spool mounts built in. Like these:

https://www.amazon.com/Motorcycle-Ac...1517483&sr=8-1


The lower portion that sticks out is threaded to accept lift spool bolts. I don't know if these will work, but if the don't, there are others that should with a little modification......sean


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Last edited by Apriliarider; 10-19-2019 at 5:42 PM.
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post #19 of 19 (permalink) Old 10-19-2019, 6:18 PM
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Originally Posted by DannoXYZ View Post
Ah, I had hoped you've stumbled upon Ferrari's patented "ferran" process for welding steel to aluminium. Could use some of that tech. I suppose it's some sort of brazing with filler metal that sticks to both. Perhaps copper, silicon & zinc blend...
nope sorry. that's the problem with old bikes you never know how much they have been modified, bodged, altered, or played with by PO's. when you have only seen one set you assume their stock. obviously this is not the case. when I bought the swingarm for the cruiser it came complete with all the kit. I thought great less work. but no it was complete because he couldn't strip it down to sell the bits separately. LOL.
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