Starter spins, engine doesn't turn over... hmmmm....

OK, I had torn apart the entire engine, splitting the case to replace the crankshaft, bushings, rods, pistons, rings, primary chain, all the valve parts, except the valves (I lashed them), and a mess of other parts. I was extremely methodical in cleanliness and proper positioning when reassembling. I did notice some play (slide) in the starter sprocket on the secondary shaft and a little less on the idle gear. Now for some reason, there is too much play between the starter, idle gear and starter sprocket to engage the starter clutch properly. I would really like a shortcut to figure this out seeing as how I do not want to have to tear off the top end and oil pan again to fix it. Any ideas?
~Marty

Here you can see the secured idle gear...

Check the clutch adjustment in the side cover for the countershaft sprocket.
I have had the same trouble, that fix it.

XENU

Now that you mention it, the engine turned over a few rotations before slipping out completely and I did notice the front sprocket turned even with the clutch pulled all the way in. OK, I'll adjust that clutch pushrod in some and see what I get. Thanks,

If its not the clutch, check the rotor to make sure it is properly torqued. Mine got loose and starter spun without catching the gear. Good luck

Would this also cause the starter to take turns slipping and catching?

That is what mine did. Took a while to figure out what was going on. If that is the case make sure the rotor is not wallered out where it goes on the crank, I replaced mine, torqued to spec and made sure I used loctite.

OK, no go. I got a great clutch adjustment and still the starter just spins the idle gear. I did notice that the bearing cap under the starter was never seated fully, half the cap gasket is exposed. Apparently, the shaft and bearings are in too far (I say in, because it gets removed from the other side) and prevent the cap from seating. That is the same direction the starter sprocket is offset from the idle gear. I second guessed myself on whether I put the sprocket on backwards or not but after a look at the secondary shaft diagram, I know I followed it properly when reinstalling.
Right, so I tried tapping the shaft and bearing in further but made no progress. What can I do to adjust the shaft allowing the bearing cap to seal/seat and the starter sprocket to engage?

Let me just emphasize my extreme need to solve this problem. I AM DESPERATE!!! Short of pulling the engine back off the frame, removing the heads, flip... removing the oil pan and dis/reassembling the secondary shaft, I have no idea how to get her running again.

Sincerely,
Sleepless in Susquehanna

Well, I guess the engine comes back out today. I'm thinking I can just drain the oil, flip it with the heads on, pull the clutch and oil pan and be able to figure this deal out with the secondary shaft.

I think my KZ1100 is doing the same thing. When I hit the starter button the motor will turn over but then it sounds like the start stops engaging and does a little grinding. Any luck getting this fixed? If so, what finally worked?

OK, the secondary shaft was almost a 1/4" off towards the main clutch and both bearings were about 1/8" out from flush with inside seats. A little tap, tap, tap after a pull, flip and oil pan removal and... TAH DAH! Put her all back together on the frame and she turns over well. Next problem, NEUTRAL light on, yet still in gear. Thats the next topic. I'll post later today.

BTW sagreen13, I kind of doubt that could have happened to a running bike, but it may be worth a check.