Holey-Kaw, I am finding holes!

Hello -- This summer I bought my first bike, a 1980 750 ltd twin, and I have been working to get her running (learning as I go) but I have run into a problem that I was hoping someone might be able to help with.

When rolling back into the garage, the chain locked up because one link snapped. The chain was pretty much a rusty, greasy mess (prior owner was not much on maintenance - and it was on my to-do list to replace, but I hadn't gotten there yet). So, trying to do this the right way, I checked out the sprockets - back looked worn but front okay. I ordered a new chain and am still looking for a rear sprocket.

Yesterday, I took the chain off to give the frame a good degreasing before replacing the chain and sprocket and discovered a dime-sized hole in the transmission cover, a slightly bent clutch push rod and busted chain guard (by the engine sprocket - hence the hole). So, now I am thinking I need to remove the engine sprocket to get the transmission cover off to replace both the cover, guard and the clutch push rod.

Could anyone please advise if I am headed in the right direction? And, if so:

(1) How do I get the blasted bent-tab washer off the nut holding the engine sprocket on? (That PITA is not wanting to budge and I don't want to break anything by going at it the wrong way).

I see from the posts one way to get the engine sprocket nut off is to put the chain on, engage the rear brake and either impact wrench (or elbow-grease the daylights outta) the nut. (2) Is this correct? (3) And, if I do that, am I going to ruin (or weaken) my new chain?

Thank you to anyone and everyone that can help. I really appreciate it!

if the washer is folded up against the nut on the sprocket just straighten that part,once the nut is off the washer will come off with the sprocket

You really should replace both sprockets with the chain. These parts wear together and an old sprocket will prematurely wear out a chain, even though the sprocket has some life left in it. Also, it is important to replace that engine sprocket washer with a new one; they are still available from Kawasaki. Don't take the chance on damaging your new chain using it to hold the sprocket. Use a piece of the old chain as shown below. Just wrap it around the engine sprocket and use 2 long thin bolts to fasten the loose ends to the swingarm pivot. This way there's no stress on the brake either.

That is genius! Thank you thank you thank you!!! :woohoo:

And when you go looking for a trans cover, a whole bunch of different models will fit, 550, 650, 750, etc.

From Kawasaki.com

KZ550-A1 (1980)
KZ550-A2 (1981)
KZ550-C1 (LTD) (1980)
KZ550-C2 (LTD) (1981)
KZ550-D1 (GPz) (1981)
KZ650-B1 (1977)
KZ650-B2 (1978)
KZ650-B2A (1978)
KZ650-B3 (1979)
KZ650-C1 (Custom) (1977)
KZ650-C2 (Custom) (1978)
KZ650-C3 (Custom) (1979)
KZ650-D1 (SR) (1978)
KZ650-D1A (SR) (1978)
KZ650-D2 (SR) (1979)
KZ650-E1 (LTD) (1980)
KZ650-F1 (1980)
KZ650-H1 (CSR) (1981)
KZ650-H2 (CSR) (1982)
KZ750-B1 (1976)
KZ750-B2 (1977)
KZ750-B3 (1978)
KZ750-B4 (1979)
KZ750-E1 (1980)
KZ750-E2 (1981)
KZ750-E3 (1982)
KZ750-G1 (LTD II) (1980)
KZ750-H1 (LTD) (1980)
KZ750-H2 (LTD) (1981)
KZ750-H3 (LTD) (1982)
KZ750-M1 (CSR Twin) (1982)


Amazing

Might want to check out this thread if you're looking for a parts: www.kzrider.com/forum/23-for-sale/466737...-kz750-and-650-parts
I don't know the years he has for sale, but hopefully it helps.