TOPIC:

I am looking at rebuilding the starter on my 1980 KZ440 tomorrow (first thing to fix when I get it.) I have the Clymer manual, and was looking through it, but I figure I would ask you guys about starter removal.

How do you do it. I was searching on the internet, youtube, etc, and I just cannot find anything going into any sort of detail. If anyone has any tips on this type of bike, I would appreciate it. I am getting the bike around 10 am EST tomorrow, and the first project is this starter issue. Thanks again.

Have you ever rebuilt a starter before?


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Are you absolutely certain that the starter needs to be rebuilt? They are surprisingly robust and rarely need attention. Far more common is a slipping starter clutch, a bad ground, corroded cable ends or a bad battery. What are the symptoms?

The Clymer manual is ok, but the factory service manual is more thorough and specific to your model. There may be electronic versions floating around the Internet, and hard copies pop up on eBay now and the. It is well worth the trouble and expense.

I just saw in your other thred that the bike has only 7300 miles on it. I cannot imagine the starter being worn out in so few miles.

The owner has the factory service manual, which I will get tomorrow. The starter issue is just going on hearsay. I figured why not rebuild a starter, or at least have parts for it. Removing and testing is my best way to test. I figured, at the price I paid it for, even if I have to really hunt down some issue, it was a bargain. Besides, what fun is a bike that you don't need to work on. I just wanted to try to get an idea of pulling the starter so I can test it.

As for have I rebuilt a starter? No, but I watched some youtube videos, and can usually pick up on those type of things, so I'll give her a good ole college try.

Agree. It seems HIGHLY unlikely that the starter would be shot with such low miles. It might help if you describe the symptoms. Ed

I think you may find some usefull information and a manual here
kz400.com/WorkshopManFrameset-5.html

Like everyone else has said more likely to be something other than starter motor .....like the starter solenoid or a bad connection. Follow the manual before you get in to deep

Yeah, it'll definitely be easier when I have the bike. Since it is half a mile away, part of me thought about bump starting the bike, and riding it home. It's been sitting a few years, and I am replacing all the fluids today as well, so I figured better then to ride it (The tires are old.)

Not riding it home was a good choice, even if it had started.
On the other hand, blindly disassembling stuff based on hearsay from someone who wanted to get rid of the bike is begging for trouble. I fully understand the allure of taking something apart just to see what is in there. I also know how much grief and frustration can come from creating a whole new set of problems that did not exist before. Been there, got the tee shirt.
A 37 year old motorcycle that has been sitting neglected for years will have plenty of problems to solve and more than enough surprises without creating more. I think a more methodical approach, with the help of the fsm and the mountains of experience around here, will provide you with many pleasant hours of wrenching, and at the end, a motorcycle you will be happy and proud to ride.
Ymmv

here is a start:
Got it home, swapped the battery.
Checked lights. Everything good (quick test on wiring.)
next, examine the air filter. I find a mouse nest, complete with a piece of rat poison... Not a good find, however, no penetration into the air filter, they just used the box...
Clear rat nest, and attempt to start so I can hear what is going on.


Here is what I hear: poor attempt to turn over, then click click click. I listen to the click to see it is at the starter solenoid, then try again, and here it at the starter as well. Good sign, in a way. To me, the untrained bike guy, it appears that those are good and well. now to remove the side cover (starter cover removed to view starter.)

Another issue... gas leaking both from the right side carburetor and the little "overflow" hose...
~ Upon disassembly of the carburetors, I notice a screw is missing from the float bowl. This screw has been broken off... nice present.
Clearly, at least it appears so to me, it is time to rebuild some carbs.

Pictures to be added later, because I dislike samsungs new attach a phone weird program thing.

This turned out to belong in the projects section. If a Mod can move it there, I would appreciate it. If not, I can start another thread.
Thanks.

CPLSeraphim

In most cases all that is needed for carbs is a very careful cleaning and new gaskets and orings. Avoid rebuild kits as they often contain inferior parts and parts you do not need. The petcock (fuel valve on the tank) almost certainly needs rebuilding, too.