Kawasaki Sportsbike Riders Club - Australia - Online Forum

Hi Guy's,

I decided to do the Started Clutch today. I bought the kit to replaced the springs, plungers and Rollers etc. had the gaskets and tools ready... all checked OK.

Now .... when I got the Started Clutch out, it was obvious the issues I was experiencing with the Starter wasn't the rollers etc. It was the 3 Allen head bolts that you need to remove to separate the components to get at the rollers, these bolts were replaced with mild steel bolts and that had lunched themselves severely. A quick check of the cast sections with the thread was OK thankfully, went to the local bolt supplier and purchased 3 hardened bolts for a whole $2.00. I installed them using Blue Loctite and replaced the rollers, pins and springs with the new ones as it is a one time repair.

I had a NOS sump so I installed it and put the whole thing back together, the starter works beautifully now. A lesson to anyone who is rebuilding and engine " Use the right bolts and tension them correctly", this could have ended up being an engine replacement.

Now.... the next task is to replace the camchain.

See ya
Noel

Did you replace this just through the sump Noel, or engine out and split the cases ?

These starter clutches are a real achilles heel in the 650/750 engines, the rollers stop rolling, springs stop springing, and pins unpin themselves often. Often, it can be something as insignificant as a tiny piece of crud caught in the roller grooves, which stops the rollers from engaging properly......and all you hear is the dreaded 'whizzzzzzzzz' of the starter motor spinning without engaging.......

Hi Gos,

I did the repair with the engine in the frame, it wasn't hard. There is a trick to it though, to get the starter clutch hub out you have to remove the starter driven gear from the assembly or you will never get it off the HiVo chain, there are also some other items that aren't mentioned in the workshop manual. I just took my time and it all came together nicely, gee it is nice to have a starter that actually works. Oh and I rebuilt the Starter Motor a few weeks back which really turns the engine over nicely.

I am a happy boy now

See ya
Noel

i have to do this to mine eventually....but i will be going through the sump.

Luckily i have the kick starter for getting genuine kawasaki bad knees.

Going up through the sump is the quickest way, but yeh, the manual does miss out on some of the better tips for doing this at home ! I have to do the same number on the starter clutch fitted to the z750 dirtbike, it has been rooted for a few years now, and it would be nice to have an electric boot once again.....

Good to hear you have got it all sorted mate, these clutches are also much worse when cold, but can be OK when warmed up......

Now I have the Starter sorted, my next job is the cam chain. Is there any tips around for this job? I have been told it is an easy job of about 4 hours start to finish.

Thanks
Noel

You can get some great info on rebuilding these motors here

Thanks Gos, some very useful info.

Noel

A very useful doc.
Thanks Gos

Thanks Gos I hope you dont mind I down loaded the same document cheers!