'80 LTD440 Starter Problem

Rob277 · 10-13-2008

Hi, Just bought my first kawasaki today. It's a 1980 LTD 440. Got it from a woman who needed cash to make bail for her husband. $300

The bike has been ridden pretty regularly recently as the back tire is almost worn out with no sign of dry rot. The woman told me that she believes that the problem with it was the starter solenoid as her husband had a new one to go on it. I replaced the solenoid but it still won't turn the engine over. It will turn over a little every now and then so i know the engine isn't seized or anything. The starter seems to have trouble turning. It squeals some like a bushing or bearing is worn almost like a car alternator when it's about to go out. The starter also has the cover off of it and what looks like some hammer marks where someone has tapped it to get it to turn.

Does anyone have any input or tips on this? Any would be appreciated as it's been a while since i've worked on a bike and i've never worked on a kawasaki. If I get time tomorrow I plan to remove the starter and have it checked out at a local shop. I'll post a pic of the bike. I think I did pretty good for $300.

StarGate · 10-13-2008

Nice bike for the price. If it turns out the starter is ok then I'd suspect the squeel comming from the starter clutch but it's probably the starter as long as your sure the battery is good.

xcgates · 10-13-2008

Sounds simple, but once after my bike wouldn't start for some stupid reason or other, I just needed a quick jump, and it worked just fine. And it sounded like the starter or starter clutch was on its way out. Just an idea to eliminate the battery as a problem.

TwinStarBMC · 10-13-2008

If it worked with a jump, then maybe the battery's weak? It has enough juice to sound like it's trying to start, but not enough to actually kick it over? Just a guess.

Rob277 · 10-13-2008

bike came with a brand new napa battery. which is holding a charge quite well. We did try jumping it just in case but that didn't help.

Rob277 · 10-13-2008

Just got back to the bike and decided to try a roll it over manually to make sure the basic internals are good. seeems to turn easy enough and good compression. Did notice in the process the starter seems to whine like it's hung up when i roll it. So i'm thinking maybe the clutch is hanging on the starter? Just gotta wait for some shade because it is hot as hell in the sun today.

MFolks · 10-13-2008

Like most 4 cylinder Kawasaki's the starter is on the left side with the over running clutch for the starting system behind the alternator rotor. The brushes for the starter may be worn down or the bushings for the motor may also be worn causing it to hang up.

A new side cover gasket will be needed as the old ones will tear on removal.
Lean the bike to the right to limit oil loss and carefully remove the left side engine cover to access the starting system. A large soft blow hammer works well for stubborn covers.

Rob277 · 10-13-2008

Ok just got the starter off. Hooked it up to a battery charger and at 50amps it turns very slowly and seems to grind and only turns intermittently as some times it doesn't turn at all. So now I'm thinking the brushes are wore out. Going to try to contact a buddy with an alternator shop. Also going to try to find an impact driver to get the cover off because I heard something fall.

Does anyone have any leads for starter parts or a new gasket for the cover. I have a motorcycle junkyard I might try if I can avoid working 70 hours this week. 12-15 hour days don't leave me with much time or energy one the week starts up again. Thanks for helping a kawasaki newbie guys!

StarGate · 10-13-2008

Rob, check the sticky thread in the vintage section of the forum. There is one with a list of parts suppliers for older bikes.

Rob277 · 10-14-2008

Update: I got some new brushes in the starter and it cranks like a champ now. Had a little trouble getting it started as it has been sitting for probably a year or o little over. a shot of starting fluid and she fired up. She runs but a little rough. Seems the carbs may be clogged up. It stutters if you open up the throttle, and when riding tends to rev when i let off the throttle. Choking it tends to make it run a little smoother. Could probably use a valve adjustment too. First step is to bleed out the front brake, then I'll see about a little tune up. So far I'm impressed with the bike

10-13-2008	#1 (permalink)
Rob277 Newbie Join Date: Oct 2008 Posts: 6	'80 LTD440 Starter Problem Hi, Just bought my first kawasaki today. It's a 1980 LTD 440. Got it from a woman who needed cash to make bail for her husband. $300 The bike has been ridden pretty regularly recently as the back tire is almost worn out with no sign of dry rot. The woman told me that she believes that the problem with it was the starter solenoid as her husband had a new one to go on it. I replaced the solenoid but it still won't turn the engine over. It will turn over a little every now and then so i know the engine isn't seized or anything. The starter seems to have trouble turning. It squeals some like a bushing or bearing is worn almost like a car alternator when it's about to go out. The starter also has the cover off of it and what looks like some hammer marks where someone has tapped it to get it to turn. Does anyone have any input or tips on this? Any would be appreciated as it's been a while since i've worked on a bike and i've never worked on a kawasaki. If I get time tomorrow I plan to remove the starter and have it checked out at a local shop. I'll post a pic of the bike. I think I did pretty good for $300. Attached Thumbnails

10-13-2008	#2 (permalink)
StarGate Navy Vet S.A.R. crew BTK Expert Join Date: Apr 2007 Location: NE Arkansas Posts: 5,028	Nice bike for the price. If it turns out the starter is ok then I'd suspect the squeel comming from the starter clutch but it's probably the starter as long as your sure the battery is good. __________________ Mike Original Owner 1981 KZ1000-K1 LTD 2000 Suzuki King Quad Photos

10-13-2008	#7 (permalink)
MFolks Wants better weather! BTK Expert Join Date: Jul 2008 Location: Springfield Mo Posts: 930	Like most 4 cylinder Kawasaki's the starter is on the left side with the over running clutch for the starting system behind the alternator rotor. The brushes for the starter may be worn down or the bushings for the motor may also be worn causing it to hang up. A new side cover gasket will be needed as the old ones will tear on removal. Lean the bike to the right to limit oil loss and carefully remove the left side engine cover to access the starting system. A large soft blow hammer works well for stubborn covers. __________________ Mike Folks

10-13-2008	#9 (permalink)
StarGate Navy Vet S.A.R. crew BTK Expert Join Date: Apr 2007 Location: NE Arkansas Posts: 5,028	Rob, check the sticky thread in the vintage section of the forum. There is one with a list of parts suppliers for older bikes. __________________ Mike Original Owner 1981 KZ1000-K1 LTD 2000 Suzuki King Quad Photos

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10-13-2008	#3 (permalink)
xcgates Newbie Join Date: May 2008 Posts: 22	Sounds simple, but once after my bike wouldn't start for some stupid reason or other, I just needed a quick jump, and it worked just fine. And it sounded like the starter or starter clutch was on its way out. Just an idea to eliminate the battery as a problem.

10-13-2008	#4 (permalink)
TwinStarBMC Newbie Join Date: Jun 2008 Location: Marlborough, MA Posts: 14	If it worked with a jump, then maybe the battery's weak? It has enough juice to sound like it's trying to start, but not enough to actually kick it over? Just a guess.

10-13-2008	#5 (permalink)
Rob277 Newbie Join Date: Oct 2008 Posts: 6	bike came with a brand new napa battery. which is holding a charge quite well. We did try jumping it just in case but that didn't help.

10-13-2008	#6 (permalink)
Rob277 Newbie Join Date: Oct 2008 Posts: 6	Just got back to the bike and decided to try a roll it over manually to make sure the basic internals are good. seeems to turn easy enough and good compression. Did notice in the process the starter seems to whine like it's hung up when i roll it. So i'm thinking maybe the clutch is hanging on the starter? Just gotta wait for some shade because it is hot as hell in the sun today.

10-13-2008	#8 (permalink)
Rob277 Newbie Join Date: Oct 2008 Posts: 6	Ok just got the starter off. Hooked it up to a battery charger and at 50amps it turns very slowly and seems to grind and only turns intermittently as some times it doesn't turn at all. So now I'm thinking the brushes are wore out. Going to try to contact a buddy with an alternator shop. Also going to try to find an impact driver to get the cover off because I heard something fall. Does anyone have any leads for starter parts or a new gasket for the cover. I have a motorcycle junkyard I might try if I can avoid working 70 hours this week. 12-15 hour days don't leave me with much time or energy one the week starts up again. Thanks for helping a kawasaki newbie guys!

10-14-2008	#10 (permalink)
Rob277 Newbie Join Date: Oct 2008 Posts: 6	Update: I got some new brushes in the starter and it cranks like a champ now. Had a little trouble getting it started as it has been sitting for probably a year or o little over. a shot of starting fluid and she fired up. She runs but a little rough. Seems the carbs may be clogged up. It stutters if you open up the throttle, and when riding tends to rev when i let off the throttle. Choking it tends to make it run a little smoother. Could probably use a valve adjustment too. First step is to bleed out the front brake, then I'll see about a little tune up. So far I'm impressed with the bike

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