1978 Kawasaki KZ650 --- Restorification

testarossa wrote: I'm betting that it's you're starter clutch. I don't know about removing the starter without removing the carbs. Never tried that one. It shouldn't be too hard to take the carbs off with those pod filters. The airbox is what makes it difficult.

If this kz650 is anything like a gs1100 (not really) then carb removal and installation is no problem thanks to the pods ad you said. Hopefully the rubber isnt too hard either.

I will give it a go tomorrow... Or maybe now???

I literally just got back from work and am pretty tired

I have some good news. You do not need to remove the carbs to replace the starter motor.

I will explain this as best as possible.

Tools needed: 10 mm wrench, 10 mm socket with ratchet,


1. Use your 10 mm wrench to remove the 2 bolts holding the starter motor cover just underneath the carbs. It's a pretty tight spot.

2. Use your 10 mm socket to remove the 4 bolts holding down the sprocket cover on the left side of the engine.

3. 10 mm wrench to remove the single bolt holding down the gear shift spline.

4. Now you can remove the sprocket cover. The clutch cable is connected to it so remove the sprocket cover slowly.

You should see something like this now.


5. I like to disconnect the battery when working on electricals. Follow the only wire from the starter motor. It should lead you to the starter solenoid under the left side cover.

6. 10 mm socket to remove the bolt for the starter solenoid.

7. Back to the starter motor, use 10 mm socket to remove the 2 bolts holding the starter down. These bolts are the ones that are slanted.

8. Wiggle the starter motor out and there you go.



I don't think anyone really needed that little tutorial but it will be a good reminder if for some reason I forget. :lol:

I assume that this is my starter clutch. Looks good to me.


The starter on the bottom is the replacement.


Now you guys will be disappointed. I did not yet test it out for 2 reasons. My battery is not hooked up and the bike may start up. It's not the quietest bike either. :blush: So tomorrow morning!

Turns out the starter motors are OK... Both of them. So if it wasn't the starter, then what? My next guess would be the starter clutch but how the hell am I supposed to get to that? It almost looks like I have to split the cases just to get to it... Why Kawasaki?

Still waiting for the manual to get here. Would anyone like t look it up for me?

I might just get a whole new engine...
seattle.craigslist.org/est/mcy/2711091117.html

Flaming Chainsaws wrote: ...Still waiting for the manual to get here....

After clicking on the following link, may scroll down to locate and click on the down-loadable service manual.

Click > jarlef.no/Kawasaki/Series/Z/650/z650files.htm

Good Fortune!

Sweet! Thanks patton!

Ill just go ahead and read through and hopefully ill find something about tge starter clutch. I would much rather fix it tgan replacing with a whole new engine. But if it involves too much time and work then yeah, new engine.

That'll def be the starter clutch, really common on the 650, so quite possible that if you pick up another engine you'll have the same prob. Yes, you have to split it to replace! Probably be easier to get an early model eng casing with the kick starter shaft!!

cherrymetal wrote: That'll def be the starter clutch, really common on the 650, so quite possible that if you pick up another engine you'll have the same prob. Yes, you have to split it to replace! Probably be easier to get an early model eng casing with the kick starter shaft!!

Why oh why, mr. Kawasaki....

I do see what youre saying though. Kick start means you dont really need the starter.

STOP! You do NOT need to split the cases to replace the starter clutch!!!!!!!! That is nonsense! I don't know why some folks love to give bullshit advice when they don't know what the hell they are talking about! Maybe it's their way of getting their kicks??

Take a look at the following 2 links. The first explains step by step how to replace the starter clutch without removing the engine or splitting the cases. The second gives a good pictorial of the starter clutch mechanism and what to look for once you have it out of the engine. Good luck, I hope you read this before you started ripping apart an engine for no good reason. Ed

forums.kz650.info/index.php?action=dlatt...pic=586.0;attach=873

forums.kz650.info/index.php?topic=5152.0

Replacing the starter clutch takes me about 2 hours with the engine in the frame. Not really that hard.

Apologies, I'd not seen that method of doing the starter clutch before, when I bought my 650, the starter clutch had been done by previous owner and he claimed he'd split the engine to do it.
I know on the 900 the starter clutch is very much more accessable and easier to do. Still looks like a bitch to do the 650, and that 2 hours with engine in frame must be a real skill!

Note to 650ed - this was not bullshit advice, it was what I'd been led to believe, I certainly don't get 'kicks' out of it. I hope YOU never make a mistake....

cherrymetal wrote: Apologies, I'd not seen that method of doing the starter clutch before, when I bought my 650, the starter clutch had been done by previous owner and he claimed he'd split the engine to do it.
I know on the 900 the starter clutch is very much more accessable and easier to do. Still looks like a bitch to do the 650, and that 2 hours with engine in frame must be a real skill!

Note to 650ed - this was not bullshit advice, it was what I'd been led to believe, I certainly don't get 'kicks' out of it. I hope YOU never make a mistake....

I make plenty of mistakes. But telling a guy "That'll def be the starter clutch, really common on the 650, so quite possible that if you pick up another engine you'll have the same prob. Yes, you have to split it to replace! Probably be easier to get an early model eng casing with the kick starter shaft!! " is not one of them. Since you appear to be sincere I would make the following suggestion - before you give advice that may cause someone to spend a bunch of time and money, and may result in a damaged engine if he makes a mistake when splitting or assembling his engine, double check your "facts" and provide the source (such as the links I gave) to back up your understanding. Telling someone they must split the cases and suggesting he get another engine casing just because some clown told you that's what he did is unacceptable. Happy Thanksgiving. Ed

I havent torn into the engine yet, surprisingly :lol:

So... Just to confirm. When i hit the starter button, the starter turns but most of the time i hear a grinding noise (want a video?) and the starter motor does not catch. Is this because of the starter clutch?