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Discussion Starter · #1 ·
Hey all, my 2012 Kawasaki KLX140L won't start. The starter motor will spin just fine, but the engine won't turn over. I mean, it may give one exhaust note every few seconds, like it catches once, but mostly it's just a whining sound from the starter and gears.

At first I just assumed the starter motor little gear on the end was just worn, without doing much diagnosis. So I purchased a new starter and replaced it. Same problem.


Upon further inspection, the starter motor is spinning the idler gear set just fine. I removed the cover and spun the starter while pressing against the larger gear to keep it in the cavity. It spins with the starter.

43130


So then it must be the gear behind that, that disappears into the case. I put a "??" on my photo of this gear. I can spin it with my fingers easily...it will spin both directions, but sometimes gets hung up when trying to spin it clockwise, if I recall. What is this gear and is this normal? I would guess this might be connected to the flywheel, and if I can spin it with my fingers, well, that would be bad.

43131


Is this a common issue I might be having? I'm unable to search out anything with my symptoms. What might be my next steps at diagnosing, and/or fixing!?

Thanks for any help,
 

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Hey all, my 2012 Kawasaki KLX140L won't start. The starter motor will spin just fine, but the engine won't turn over. I mean, it may give one exhaust note every few seconds, like it catches once, but mostly it's just a whining sound from the starter and gears.

At first I just assumed the starter motor little gear on the end was just worn, without doing much diagnosis. So I purchased a new starter and replaced it. Same problem.


Upon further inspection, the starter motor is spinning the idler gear set just fine. I removed the cover and spun the starter while pressing against the larger gear to keep it in the cavity. It spins with the starter.

View attachment 43130

So then it must be the gear behind that, that disappears into the case. I put a "??" on my photo of this gear. I can spin it with my fingers easily...it will spin both directions, but sometimes gets hung up when trying to spin it clockwise, if I recall. What is this gear and is this normal? I would guess this might be connected to the flywheel, and if I can spin it with my fingers, well, that would be bad.

View attachment 43131

Is this a common issue I might be having? I'm unable to search out anything with my symptoms. What might be my next steps at diagnosing, and/or fixing!?

Thanks for any help,
Hey all, my 2012 Kawasaki KLX140L won't start. The starter motor will spin just fine, but the engine won't turn over. I mean, it may give one exhaust note every few seconds, like it catches once, but mostly it's just a whining sound from the starter and gears.

At first I just assumed the starter motor little gear on the end was just worn, without doing much diagnosis. So I purchased a new starter and replaced it. Same problem.


Upon further inspection, the starter motor is spinning the idler gear set just fine. I removed the cover and spun the starter while pressing against the larger gear to keep it in the cavity. It spins with the starter.

View attachment 43130

So then it must be the gear behind that, that disappears into the case. I put a "??" on my photo of this gear. I can spin it with my fingers easily...it will spin both directions, but sometimes gets hung up when trying to spin it clockwise, if I recall. What is this gear and is this normal? I would guess this might be connected to the flywheel, and if I can spin it with my fingers, well, that would be bad.

View attachment 43131

Is this a common issue I might be having? I'm unable to search out anything with my symptoms. What might be my next steps at diagnosing, and/or fixing!?

Thanks for any help,
Hi Gunn,
You need to remove the alternator cover, rotor and check the starter clutch (one way bearing) behind the rotor is functioning correctly. The gear '??' should only turn freely in one direction.
I have a KLX 250 and the starter mechanism is the same. The clutch-oneway part number for a KLX 250 is 13194-1091 BUT i don't know if it's the same for your bike.
 

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Discussion Starter · #3 ·
Hi Gunn,
You need to remove the alternator cover, rotor and check the starter clutch (one way bearing) behind the rotor is functioning correctly. The gear '??' should only turn freely in one direction.
I have a KLX 250 and the starter mechanism is the same. The clutch-oneway part number for a KLX 250 is 13194-1091 BUT i don't know if it's the same for your bike.
Thanks for the great info. I will do as you said and check it out.

But I did mess with that gear I marked with ?? previously and:

  • It will spin counterclockwise with my finger
  • It will NOT spin clockwise, as seen from the left side of the motorcycle.

So maybe that may mean this one-way bearing is OK...?

Here is a photo of the idler gear...maybe the smaller teeth that mesh with the one-way gear are worn and causing it to slip or not engage? Can't quite say as I've never seen one new...what do you think?

Thanks again,

Tom

43170
 

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I am confused. Earlier you wrote in reference to the ?? gear that "it will spin both directions, but sometimes gets hung up when trying to spin it clockwise"

But now you say it will only spin in one direction. What changed?
 

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Discussion Starter · #6 ·
I'm confused too.
I still think there's a problem with the starter clutch one way bearing.
Sorry guys, the first time was just a quick glance...I had no idea what that gear was. But I went back out after learning and with some new information and messed with it in detail. That is when I could report that it would spin in one direction, but not the other. Now, I did even confuse myself so I kept trying to get it to rotate CW, but it wouldn't. Now this is just a finger test, applying no where near the torque of attempting to start it.

Seeing as this is a somewhat common issue, and my symptoms seem to fit, I'm going to continue to teardown and check that bearing.

Thanks,
 
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