Starter Clutch: '81 KZ 750 LTD (4 cyl)

I'm trying to remove the starter clutch from the crankcase
How do I disengage it so I can slip it off the secondary shaft?

Hi Dave,
I fixed my starter clutch a while ago.
U can do it with the engine still in the frame. You just tap the crankcase out carefully form the right to the left and the starter clutch and chain will be so loose so you can take it off the sprocket on the secondary shaft.
It´s not that hard...you´ll work it out fine.

See the thread below for some more info.

/Arnold


kzrider.com/index.php?option=com_kunena&...d=2&id=182273#185849

Correction !! The shaft comes out from left to right.

It worked!
I had some difficulty gatting the secondary shaft out
The Clymer Manual says to give it a few taps and pull it out.
In reality you need something long with a blunt end and have to do alot of tapping on the left end before it comes out the right side
The starter clutch slips right off of the chain and comes out in one piece.
Hint: there is no need to take off any circlips.
Here are some pix

picasaweb.google.com/davehayward1/Starte...uDoejfWg&feat=email#

Thank you!!

Here are some pix of the starter clutch
One of the springs was broken
Amazing a little thing like this could wreak so much havoc!

Now - to put it all back together and see if it works!

picasaweb.google.com/davehayward1/Cluch?...v1sRgCPKirYjtkcyfWA#

Good to hear that you got it working again !

I agree, a small broken spring and the bike is almost useless.

Well - - it's almost fixed

Before I repaired the starter clutch it would not start at all - just the "rattling" noise when I pushed the start button

I still get the rattle but infrequently
My guess is - it'll get worse if I don't do something about it

Sounds like I'm shaking gravel in a coffee can

Something else is going on and I haven't got a clue - - -

Try this check list for possible solenoid problems:

Starter Solenoid Checkout

Some simple steps to determine what is working and what's not:

1.Fully charge and test the battery(most bike shops can load test the battery, and then use a floating ball hydrometer to check specific gravity in the charged cells).

2.Clean all battery terminals of corrosion.

3.Tighten all starting related connections(Positive RED(+) battery terminal, Negative BLACK(-)terminal) and from the terminal to the engine case. All connections must be clean and tight.

4.Clean the cable from the starter solenoid to the starter motor.

5.Clean and check the "bullet connectors" going to the coil side of the starter solenoid.

6.Try again to start the bike.

7.If no luck, go to step #8

8.Wearing eye protection, bridge with pliers or a screwdriver the two heavy duty(large)terminals on the solenoid. If the bike cranks, your solenoid may be bad.

9. If the starter won’t turn over, one of several things has happened; The starter motor has seized due to brushes binding up, lack of lubrication in the bushings of the motor, the battery is weak , the engine has seized or it could be a combination of any of the above. Some websites for starter motor rebuild kits are:
A. www.mawonline.com/newsite/rick_s_motorsp...-starter_brushes.htm
B. www.cyclewareables.com/pages/street_star...kits/startmtrkit.htm


10.The dealer may want $$$ for a new solenoid, but take your old one along and visit the nearest riding lawn mower shop. They have solenoids for about $15 that with a little work will fit.

11. I’d recommend upgrading from the existing battery cables to at least 6 gauge welding cables.
They are available in two colors(RED and BLACK) have more flexibility due to being constructed with finer conductors, and will fit in tighter areas.

12. The welding cable is sold by the foot ,so take careful measurements or bring your old cables along. Most battery shops might be able to supply the cable too, so call to find out. The battery shop should be able to crimp/swage on the end of the welding cable the terminal ends or lugs using either a dedicated crimping machine or a tool that looks like a bolt cutter that has special dies to terminate the cable.

Thanks!!