starter clutch problems

i think my starter clutch is giving up, when trying to start it it makes a lound crunch noise, like a hammer hitting a hollow steel box with rocks on top of it. its progressivly gotten worse to the point wher it does it almost every revolution of the crank, i looked at z1 enterprises for a starter clutch kit but haven't had any luck, any one know where to get one or how to make it stop crunching.

i'm hoping to take my bike to rock falls on oct 6th and i don't want this to fail on me when i go to fire the bike up.:pinch:

i had the cover off, so i whent back out to the garage to look at the rotor, i figured i'd go ahead and pull it off now to se if it is the clutch, i look in the three holes that the puller screws go into, and some idiot broke some motha f***in bolts off in them!!!


aww ****!

any advice on getting that rotor off, should i take my wood maul to the sob?

You will have to carefully center punch
the broken bolts and drill them out.Use
the size drill for a tap the size of your
puller,tap the threads and pull it off.
When mine went I just bought an OEM Kawasaki
starter clutch,you should still be able to
order one.I put a new stator magnet assembly
on also as one of the magnets was starting to
work it's way out.

themachine wrote:

i had the cover off, so i whent back out to the garage to look at the rotor, i figured i'd go ahead and pull it off now to se if it is the clutch, i look in the three holes that the puller screws go into, and some idiot broke some motha f***in bolts off in them!!!


aww ****!

any advice on getting that rotor off, should i take my wood maul to the sob?

I don't know your model, and I don't mean to sound ignorant, but do you mean broke like this pic? This is what happened to mine. But my rotor puller just used the center shaft, and the three bolts are to hold the rotor to the starter clutch housing.:



Post edited by: Biquetoast, at: 2007/09/21 11:37

Get a rotor puller and pull off your rotor. The starter clutch is/ should be, attached to the back of the rotor by three bolts. If the bolts were broken off, like the picture, and mine were, the broken part of the bolts should come out easily or you can drill and use an easy out. Mine came out when I tried to drill them. I got a set of replacement rollers and springs at Bike Bandit. I think Z1 has the rollers too. You might not need to replace the clutch piece, just the rollers and springs. That way has worked for me twice. Bike Bandit has a complete clutch assy if you want to go that way but it is not cheap. There are starter clutched on ebay pretty often but you don't know if it is better than the one you have. Rotors are regularily on ebay too. You just have to be lucky to get one cheap. When you put the thing back together use loctite and a torque wrench or you will have the problem repeat itself. You should be able to reattach your magent with JB weld. You just need to do a good job of degreasing on the magnet and rotor housing first. Have fun....chris3

i had to put my bike against a wall to get the nut off

oh i see how the puller works!!! dam gm engines are throwing me off!!!

where can i get/fabricate a puller from????!!!!

themachine wrote:

...where can i get/fabricate a puller from????!!!!

I got mine from www.z1enterprises.com

On many bikes the rear wheel axle can be used as a rotor puller.

And if Z1Enterprises can't supply a starter clutch rebuild kit you can get it from Partsnmore.

www.partsnmore.com/cat_index.php?model=k...&category=electrical

One thing to try is to take the bolt out of the end of the crank and then hit the starter button. Since the J model motor has a pressed on magnet rotor combination somtimes this will loosen them up and they will come right off.