Starter clutch problem with 1991 ZX600R Ninja

I have a problem with my starter clutch. I have to put the bike in gear and push forward while pushing the starter button in order to get the starter to engage the engine. Otherwise the starter will just spin free. What exactly is the problem? It looks like the engine internals would be accessable from underneath. It looks like the oil pan can be dropped with the engine in the frame. Has anyone else had this problem and how did you fix it? It also seems a bit hard to shift into 2nd gear and third feels next to impossible (this is when it's not running). Are these things related? :blink:

((((BUMP)))) Any help here guys? Anyone?:side:

You may be able to get to the starter gears from the bottom of the engine, Onkelb wrote a thread about doing it on his KZ650. I don't know how different the Ninja 600 engines are tho. Onkelb has this starter clutch writeup here on kzrider tinyurl.com/3yot5g

Hard shifting can be bent shifter forks. I think they are relatively easy to check, but I never had to do it so I can't say for sure. But if your engine isn't running then you may have another problem . Kaws have the "Neutral finder" system which lets you move from Neutral to only first gear and back again to Neutral when the engine is OFF. You can't get to second gear nevermind third when the engine is off. If you can get to second or third then I would say this system is buggered on your bike..

Post edited by: OKC_Kent, at: 2007/08/30 13:31

Post edited by: OKC_Kent, at: 2007/08/30 13:49

that is a case splitter

getting to the sprag clutch through the oil pan in the frame is impossible and dont forget the balancer shaft is right in the way on the liquid cooled engines

gpz 750 is a tough job through the oil pan but dooable

pull engine take all side covers off split the clamshell and bam!! there it is pretty easy considering

I've done a few at the shop and on my own after buying the bike for next to nothing!! and 10-12 hours later zooom!! zoom! sweet ninja power

get new parts because a used one will have you doing it again I know from the hard way

Post edited by: trippivot, at: 2007/08/30 15:10

while you have it out the transmission gears and shift forks will need to be inspected the two problems are not related but engine cases need to split to solve either or both problems

Hmmm...I was afraid of that. Can I get those parts (starter clutch) from an aftermarket source or are these dealer only items?

kawasaki only