FOR THE LOVE OF GOD PLEASE HELP ME

can someone please tell me where the washers and spacers go on the jack shaft with the starter clutch
its a 1980 kz750 four. I have two flat washers/spacers and one tappered washer, (i guess thats what it is). I can get the starter clutch assembly and all that back together i just cant remember which way the damn washers/spacers go.
thanks
Rob

talked with god this morning,he said he only works on 900-1000s but hes sure somebody on here can help you out !:whistle:

I dont have a definitive answer for you but maybe this will help if I can attach the pic correctly.

If not. go to www.kawasaki.com . Click on owner info. Click on parts diagrams, then motorcycles. For the year select 1982 (trust me on this) and 750 etc etc
.........................................
Woodstock ON Canada
1980 kz850E1, 4->1, K&N pods

Post edited by: jr, at: 2006/02/21 22:14

Post edited by: jr, at: 2006/02/21 22:16

unfortunatly its missing one, and it doesn't make sense that a washer would go between the starter sproket and starter clutch

wireman wrote:

talked with god this morning,he said he only works on 900-1000s but hes sure somebody on here can help you out !:whistle:

Haha, wireman, that's funny! :lol:

savedrider wrote:

wireman wrote:

talked with god this morning,he said he only works on 900-1000s but hes sure somebody on here can help you out !:whistle:

Haha, wireman, that's funny! :lol:

LOL!!:laugh: :laugh:

rspector wrote:

unfortunatly its missing one, and it doesn't make sense that a washer would go between the starter sproket and starter clutch

Actually it does make sense, the starter sprocket is not attached to the starter clutch (I just went out and checked to verify), the starter clutch attaches to the countershaft gear that is driven by the HyVo primary chain. It looks to me like the sprocket bearing just slides into the sprocket, and it needs something there to keep the bearing from siding into the clutch.
The starter clutch spins continuosly, while the starter gear only turns when the starter is engaged.

I'm looking at a GPz750 motor with the starter clutch and gear still in it (and I'm not going to disassemble it just to answer your question), but I'm pretty sure they are the same.

Took my flashlight and had a close look

Starting from the oil pump drive gear.
Washer (fairly thick)
Starter drive gear
Washer (The starter driver gear sticks through the starter clutch so it's actually between the starter clutch and primary drive gear.
Primary drive gear
Thin washer (maybe a cup or bell washer?) probably the one you called tapered.
Countershaft bearing.

The reason that all the washers are not shown in the above diagram is that is a starter drive diagram and don't show the countershaft.

Hope you appreciate this, now my feet are froze (probably should have put shoes on before I went out) :laugh:

Like Steel says there is a flat washer on either side of the starter clutch sprocket (2 x no. 15 in the pic below, no. 16 is the needle roller bearing sitting inside the sprocket).

The tapered washer (no. 21) sits right behind the secondary shaft gear (no. 22) outside of the right side bearing (no. 18). Install the starter clutch and secondary shaft/bearing, then install the bearing retainer bracket (no. 19) before you install the tapered washer and secondary shaft gear/circlip (no. 23) - the washer should have the tapered side facing the engine (flat side out).



Post edited by: onkelb, at: 2006/02/22 15:22

Ah, what I thought was a washer was the back of the circlip (between the primary gear and the bearing).
Thanks for correcting that, I really hate giving bad info

No problem, didn´t think you were giving "bad info" though, I try to avoid that too (which often means just keep my trap shut), I just caught the taper thing, took a 650 engine apart recently.

The tapered washer is meant to keep the secondary shaft gear clear of the bearing retainer plate, it´s tapered on the inside so it touches the inner shaft bearing ring only and not the outer ring.

When removing a stuck sec. shaft gear the spacer has another (maybe unintentional) use: at least on the 650s there are three threaded holes in the gear, by screwing three 8mm bolts into these holes the gear will turn into it´s own puller, just turn the bolts in gradually and the gear will come off - the bolts will press on the (thick) steel washer rather than the alu case or the bearing. Plus you just saved the money for the "special Kawasaki tool" that my Clymer claims is necessary to remove the gear....

Post edited by: onkelb, at: 2006/02/22 16:14