Starter clutch issues to check?

Hi all,
I've had starter issues: the typical can of rocks noise, and the starter only engaging some of the time, etc. so I was convinced it was my starter clutch. Now that I've pulled the clutch and inspected it, I don't see any major issues or differences to the brand new one I bought. Can a starter clutch be bad without having any physical damage visible? I'm going to put the new one in for good measure, but I'm concerned that I may not solve the issue, and would have to crack open the bottom end again to find the real problem. I'd rather get it right the first time, and get riding... Any thoughts? Thanks.

Hi Caleb,

Look very closely at the springs and cups that push the rollers against the boss. Chances are that one or more is worn/chipped/cracked or crushed. Generally replacing the rollers, springs and cups will get the clutch working again, although to work as good as new the boss/ sprocket needs to be replaced also.

Good Luck

Bill

Take a look at the starter clutch diagram below. Are there any pieces in that diagram that you do NOT plan to replace? Ed

Look at the spring lengths. Most likely if there is no noticable physical damage the springs are loose and not applying the same force to engage the clutch. When I replaced mine they were a little bit shorter but compressed easier.

Yeah, I pulled the springs out of the old clutch and they seem weaker than the new ones. Hopefully this does the trick. I did notice a bit of slack or wiggle between the inner and outer coupling where the main chain drives the secondary shaft. Is it normal to have a little play (2mm of travel) here? Or should I go ahead and order new rubber dampers? I appreciate the quick responses. I'm pretty new to working on bikes, thanks for your patience.

I'll try once more .....

www.kzrider.com/forum/2-engine/432739-st...heck?start=20#631683

Thanks, Ed. I've replaced 13193, I am not replacing 12406, the teeth show no signs of wear, it is straight and solid.

If is was mine and I was going through the trouble of replacing the other pieces I would also replace 12406. I suggest you at least check it VERY carefully before deciding not to replace it. It isn't the teeth that are a problem The problem is the race that the rollers engage. Take a look at the images below and notice the wear on a used part compared to the surface on a new old stock part. Those ridges on the surface of the used part cause the starter clutch to slip even with new rollers, so check to see if yours looks like the used part or the new part. Ed

Ed, Thanks for the pics. This helps me to understand so much better. Yes, mine is worn like the one in the picture and to my budget's demise, I've ordered the starter sprocket as well. As much as I love working on this thing, I'd rather be riding it than fixing the same thing twice. After this, it's on to the carburetor issues.