parts list for starter clutch rebuild

When my son comes home for Christmas break our plan is to replace/rebuild the starter clutch on his 1980 KZ750H/E (four). In anticipation of that event I thought I'd drop the oilpan and take a look to see if it's obvious what parts would need to be replaced so I could order them. It can take days/weeks to gets parts to Alaska. Well with the oilpan off now and looking at the starter clutch area from the underside, there are no obviously messed up parts. (the way it grinds I expected to see chewed up parts all over the place). So the parts I'm sure we will need are three each of ROLLERS, PINS, and SPRINGS, as well as GASKETS for right side clutch cover & oilpan. Does anyone know what the likelihood is that we will also need to replace the 58T STARTER SPROCKET and/or the CLUTCH-ASSY-ONEWAY? On one hand I hate to order a $75 part if we don't need it but then again if we do need it, it may not arrive in time to finish the job before Tim heads back to college. Any thoughts on this from any of you who have already done this repair?

Contact www.z1enterprises.com for parts. www.kzzone.com,www.dynoman.net,www.sudco.com,and www.redlinecycle.com , www.partsnmore.com,www.vintagecyclepart.com are other websites to try.

There was a starter clutch on eBay for cheap. I think it was for a 900 but the small parts might interchange. I think i have used 650 small parts before. Roy

roy-b-boy-b wrote:

There was a starter clutch on eBay for cheap. I think it was for a 900 but the small parts might interchange. I think i have used 650 small parts before. Roy

The springs and plungers may be the same, but the rollers are different sizes between the 650/750 and the big bikes.

I did the same job on a KZ650. I ordered the rollers and the springs first. Assembled everything it did the same wrattling noise. At the end I had to change the all assembly and the sprocket. I could not find any documentation about the wear limit of the sprocket and the rollers. From my personal experience, and since lead time is an issue for you, I would suggest to replace the all assembly plus the sprocket.

Good luck.
Fred

normally what happens with starter clutches is over time the bearings will flat spot and the bearing surface will do the same so normally you have to replace both components at the time. the flat spoting is what is causing it to stay engauged. so replace the rollers and ring gear assemblly and you should have no more problems.

Gary, The most common failure w/starter clutches is/are what appear to be minute divots on the inner sprag surface,causing rollers to bounce instead of lock. thus a spinning starter and intermittant knocking sound from general area. I recommend a new inner sprag and rollers. if caps run smoothly in bore, and springs are intact, they and their recievers are seldom the problem, tho due to the time & effort to get there, you must be the judge. G

Well, we did it!
Thanks to all for the above advice. We went ahead and had on hand the entire clutch assembly including the large sprocket. We did it with the engine remaining in the frame. Removed left (chain sprocket) cover, alternator cover, exhaust, clutch cover, clutch, oilpan, and oil pump. Had to make the clutch holder tool to get the 30mm nut off. Secondary shaft slid out smoothly. Replaced all clutch parts as mentioned, and it went all back together without a hitch, well maybe some small ones. Now it turns over easily, every time, no grinding or spinning as before.