TOPIC:

Hey guys, I;ve taken apart the starter clutch assembly to put in the new barrel rollers, springs etc. and have noticed some wearing in the clutch where the rollers sit, and on the face of the coupling.... please see pics
do I have to replace both? or can I refurb them ? I found some "amberish" looking substance within this area; some stuck under one barrel polished like, glass, could it be some resuidue? Could this have been the problem ?
If I need new parts, I see they are discontinued on Partzilla, and a few near years on ebay, probably won't fit.
Anyone have this art for a 78 sr d1 ?
Thanks for any advice. m

Please add your bike's model and year to your signature line. While you have the starter clutch apart check the starter clutch gear where the rollers ride. When worn it can cause the starter clutch to slip. Pic below shows what I mean. Ed

Looks like normal wear to me. How do the pinch bearings, springs and plunger look? The race can be cleaned up with some emery cloth. You want to check the bearing on the crank as well.
Steve

Just re read your post. That's what you meant by barrel rollers. With the new parts and a good clean up,it should work fine.

Thanks Ed, I can't see any part like that one, The Coupling has a surface much like it though (in Pic1) .
Steve thanks as well, The rollers and pins and springs all looked good (springs a little shorter than new ones. So a good emery clean, to take out some of the scoring should be alright then. I'll check all pin bearings etc. Amazed how well the inside looks after almost 40 years !

KZGoodchild wrote: Thanks Ed, I can't see any part like that one, ....

The part I showed is shown as #14 in the Kawasaki parts diagram below. Your bike has one. Ed

Right Ed, I see it now, the cut outs on yours through me. It was also sitting on my bench knurled side down, and has no texture at all. Is smooth. So I guess I need to order one. Two wheel pro seems to have them.
Looks like the rest,l have to wait till the new year ! Thanks a bunch,
Btw I am just cleaning up the clutch and coupling, they seem in pretty good knock, I don,t kno what I would,be done if I had put it all back together and not changed the gear though, thanks a bunch. I is good to be a member here. Cheers. Mike.

Ah, yes. Some have the cutouts and some don't. I don't know when they made the switch. Ed

Thanks Steve, do I look for excessive play in the needle bearings, or wear/scarring?

Yes. They should be alright though. They mainly just spin with no load most of the time unless there was a oil issue.
Steve