Starter motor wont engage long enough - Page 3 - Kawasaki Motorcycle Forums
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post #21 of 31 (permalink) Old 05-04-2016, 03:52 PM Thread Starter
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Q) did you buy a new starter cluch or a second hand one off ebay ?

Q) how much of the assembly did you buy ? all of it or just the bit that takes the springs and rollers ?

Q) How did you get the secondary shaft bearing back in - the one that comes out on rhs ?
Just wandered what technique you used or did it just slip in ?

As i have a second engine that is knackered i am going to use the starter clutch from that
and put the kit into that one.
One thing with it is that the cush drive type of rubbers must be perished a bit as the assembly moves.
I dont think this should happen and it doesnt happen on my "faulty one" .....
So out of the two i am going to make one that i think has a chance.

At present it is as you say a two weekend job ! I agree totally.
The biggest issue is getting the gasket off the sump and clutch cover !

All this however is still easily (yes easily) possible with the engine in.
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1982 GPZ 750 R1 Owner
1980 GS 550E
1977 RD250
1980 GSX 250
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post #22 of 31 (permalink) Old 05-04-2016, 06:51 PM
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I bought a brand new whole starting clutch. Complete. The person I knew did not succeed at first with rollers and springs, said he resorted to a used one from a Z650 (KZ650 in US). Said it worked.

It was at least 8 years ago I did this, but I believe the right bearing simply slips out. I do not recall any problems there. The left one stays in place, there is a bushing there.

Yes, like I mentioned, it is better to pre-order all rubber parts and the cush drive is one of them. Old one would still work, but a new one is always better. Another thing I regret not having ordered was a torque rod/socket to tighten back the clutch nut with the impact gun.
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post #23 of 31 (permalink) Old 05-05-2016, 02:36 AM Thread Starter
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All points taken on board.
I think being a risk taker and the fact that if the gaskets are on with a mind to removing them ( they will be ) , I am going to replace with only new springs etc.
Removing the stuck gaskets took the longest time.

Having done this if it fails I can sort next time in a weekend of leisurely mechanics with the engine in .

To get new parts for me from cmsl or someone takes almost a week.

The bike sits 3 hours from starting awaiting the kit to arrive .
I will inform of results and if it fails in say 6 months after.

I am also trying to think if I can test without covers on .......
Just to see if it turns over ? No oil , not able to start for 2-3 seconds only? Allowing simpler disasembly

1982 GPZ 750 R1 Owner
1980 GS 550E
1977 RD250
1980 GSX 250
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post #24 of 31 (permalink) Old 05-05-2016, 04:55 AM Thread Starter
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P.s you did not say how you got the rh side bearing back in ?
The one that comes out attached to secondary shaft ?

Freeze it ? Heat engine socket ? Large socket and hammer ?
How did you do it ? Just interested

1982 GPZ 750 R1 Owner
1980 GS 550E
1977 RD250
1980 GSX 250
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post #25 of 31 (permalink) Old 05-05-2016, 08:38 PM
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To my recollection, I did not remove the rhs bearing from the shaft. Simply installed the starting clutch through left end, and shaft went back in. It is always a good idea to change bearings, but I did not do it.

Factory manual shows a puller to remove it, and a bearing driver (and hammer) to install it.
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post #26 of 31 (permalink) Old 05-06-2016, 02:22 AM Thread Starter
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No no,

How did you replace the bearing into the casing ?
I am interested to know how you did this ? The bearing that comes out on the shaft on the rhs ?

The bearing needs to be driven back into the casing.
I am asking as I wanted to know how ? Did you heat casing , freeze bearing use a large socket and hammer ?
I am not interested in the manual only how you did it ?

1982 GPZ 750 R1 Owner
1980 GS 550E
1977 RD250
1980 GSX 250
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post #27 of 31 (permalink) Old 05-06-2016, 05:36 PM Thread Starter
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starter clutch in and fixed

Finished the starter clutch project today.
Hugojose you are right to say it is a 2 weekender project. I did it in three easy days , could have done it in 2
if I had all the parts and had done it before.
Anyway mine works now. It I would say is 98% perfect.
I used the kit only - I took a risk purely to know.

So:
It is easy and you can easily do it with the engine in ! It is if you take you time almost enjoyable.

You must have a electric impact gun, a good impact driver for philips bolts and be methodical.
You also need a massive socket to use as a bearing press. used a 46mm to get the baring back in
on the rhs. no real need for freezing and heating ...

On mine I only used the repair kit, springs, rollers and bushes.
I cleaned the areas where these sit with a dremel brass brush and sanded with 1500 wet and dry
to make the surface totally smooth - yes a risk but it is purely a mechanical operation.
I had to clean the internal threads out of the starter clutch too.
I put it all back together with molyslip lubricating the rollers.

All back in within 3 hours and now works fine.

also i used a list from a this site. i did a search for starter clutch repair and this chap did a list
of every step. So concise i barely needed to look at the haynes, or workshop manual.

I might try and write this up but presently i am burnt out with this bike.
If anyone wants help let me know.

Cheers hugo - your the man who said it was possible when the engine is still in.
Saved me loads of time !

1982 GPZ 750 R1 Owner
1980 GS 550E
1977 RD250
1980 GSX 250
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post #28 of 31 (permalink) Old 05-09-2016, 03:21 AM Thread Starter
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STOP - Just in case anyone is about to do a starter clutch mine has failed !
It i not as bad as it was and possibly usable when the bike is tuned but it is not right.

I agree totally with hugo you should buy the starter clutch disk (£120).
The GPZ Zone Starter Clutch & Alternator chain

I am however glad i tried to repair it - almost half knowing it might not work.
I had to know. Anyway next time ill definately buy a new starter clutch as per above thread.

As you cannot possibly tell if it is damaged you cannot possibly risk buying a second
hand one off ebay.

1982 GPZ 750 R1 Owner
1980 GS 550E
1977 RD250
1980 GSX 250
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post #29 of 31 (permalink) Old 05-25-2016, 10:44 AM Thread Starter
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@Hugojose (or anyone who has done it)

Just about to order up a new starter clutch.
did you replace just what is in my attached picture ? or the gearing etc too (pic 2)
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File Type: jpg starter clutch for sale.jpg (14.1 KB, 3 views)
File Type: jpg starter with gearing on.jpg (345.6 KB, 4 views)

1982 GPZ 750 R1 Owner
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post #30 of 31 (permalink) Old 05-26-2016, 04:26 AM
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I replaced the whole thing, including the inner race where the rollers bite into. Is the part sliding into the shaft which also contains the gear for cranking motor. That is not shown in your picture. I believe the inner race is more important than the outer casing.
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