TOPIC:

I'm doing my starter clutch, I'm following the procedure described in the PDF that is circulating around.

The instructions are clear. Removing the lick plate staked screws and the secondary shaft back plate ones has been a pain, even with JIS bits and an Impact wrench I managed to strip the heads of three.

Ungluing the gaskets is another dauntless task, those gaskets are glued and are really stubborn to remove.

Other than that it can be done with the engine on, there's plenty of space to work.

I noticed that the springs were notoriously shorter than the replacement ones. I hope this fixes the problem. Everything else looks fine so far.

This is how the older (on top) springs look compared to the new ones.



One thing Idk is if I should use some blue loctite on the starer clutch allen bolts. When I removed them there was some kind of thread locker on them.

Are you just replacing the springs? There is a roller and spring kit out there.

baldy110 wrote: Are you just replacing the springs? There is a roller and spring kit out there.

No, I replaced the springs and rollers, got them from Z1enterprises. I nust finished but I'm afraid that t didn't fix it, it improved but still slips.

Did you check the starter gear while you had it apart? A worn starter gear will cause problems. Ed

I would use loctite 648 on internal bolts. And loctite 272 for a rotor nut if it was mine.

650ed wrote: Did you check the starter gear while you had it apart? A worn starter gear will cause problems. Ed

Ed,

It has to be that, the gear was shiny but didn't look worn and I didn't feel anything on the surface.

I guess I will have to do all over again . I will buy the new gear.

I'm extremely frustrated. Yesterday I took the bike apart and replaced the gear, put it back together and I have the same issue, the starter slips.

So far I have done:
- Replace the clutch springs and parts with a repair kit from Z1enterprises
- Replaced the starter gear with a new OEM one


With the new gear I can see a slight improvement but still the starter slips when it has to engage. If the bike is at operating temperature I can starter with the electric starter, otherwise I have to kick start it.
I need advise on what could be the issue. It's is extremely frustrating being so close to have it how I want it and have this issue that I can't fix.

Should I replace the complete secondary shaft assembly?

HELP!


Ont the positive side I mastered the process of replacing the starter clutch with the bike on the center stand and the engine i the bike.

It would be best to remove the anti-friction oil or additives you have in the bike. I've been using Wal-mart oil for 10 years and haven't had any problems.

tinlizzie37 wrote: It would be best to remove the anti-friction oil or additives you have in the bike. I've been using Wal-mart oil for 10 years and haven't had any problems.

Really, that's your advise, I have never had or heard of a starter clutch acting up due to oil, it will effect the clutch but not metal to metal surface contact.
Sometimes I have had starter clutch repair kits that did not work. I end up taking two new kits and using a micrometer measure everything and pick out the best ones to use. That has worked for me in the past. I even replaced all the starter clutch components with new parts like you did and still have it not work right. On that incident I took the starter clutch gear, new and the used one and again using my micrometer I measured the surface where the roller ride on. I picked the gear which had the largest diameter, that happened to be the used one and it worked. It can be very frustrating due to the work involved, be patient.

Definitely is not the oil, I use Mobil 1 Racing 4T which doesn't have the anti friction modifiers than the ones used in cars. Tinlizzie, my problem is with the starter clutch, a completely different thing thing the engine clutch.

I guess I will have to keep trying. The measurement is a good option, I believe I still have somewhere the old parts. I will compare the sizes when I take everything apart once again, but when I do, I want to have a spare clutch assembly and I'm going to crank it with the engine open to see if it engages.

Thank you Badly, it's good to know that this happened to somebody else before.

Where did you find the new starter gear ??

I got it new off eBay. Kawasaki part number 12046-1032