starter clutch 1982 kz 1100 spectre d1

ok first some of ya know my name by now . you guys have helped me extremely. Ive been learning as is happens. well got a nother new one for me. my starter began having trouble catching , now it wont catch enough to start the engine ,espesualy when cold-winter in spokane wa- some one told me there was a starter clutch. well I pulled the stator cover hit the starter and found what and where the starter clutch was.as I said learning as I go. when I hit the starter the part with the stator magnets wasnt spinning,wich also explained the spark problem. if I repetedly hit the starter fast ,as in clicking it, some times it will grab but not enough to start. I put a socket to the bolt and turned it the direction it goes when it grabs. then the clutch grabs good a few times the again no grab. what I would like to know is do I need to replace the starter cluch - Im thinkin _ or is there a adjustment - Im a hopein - and when removing the clutch which way does the nut turn, some people have told me difernt, of coares there not bike machanics so I feel better asking here

Over Running Starter Clutch Repair On the Older, Bigger 4’S

1. When preparing to repair the starter over running clutch have a few items on hand:

A. New alternator cover gasket.
B. New springs (3).
C. New spring caps (3).
D. New rollers (3).

2. If possible, put the motorcycle on the center stand and tilt to the right to reduce the oil volume in the alternator cover.

3. Place an oil catch pan under the left side of the engine to collect what small amount of oil that will escape when the alternator cover is removed.

4. Remove the foot shifter lever, left foot peg assembly and the sprocket cover.

5. Some Kawasaki’s have socket head cap screws(Allen type) and others may have fasteners with a Phillips type. If the latter is there, a # 3 bit seems to work the best for removal.

6. Remove the alternator cover and take care with the three wires coming from the alternator stator. These are the voltage supply wires for the motorcycle. Rest the cover on some newspaper or rags to prevent damage.

7. The magnetic Rotor or flywheel will probably require a removal bolt or puller. NOTE, SOME ENGINES HAVE LEFT HAND THREADS ON THE ROTOR!!



8. The over running clutch is bolted to the back of the rotor with three Allen head fasteners.

9. Separate the rotor from the over running clutch and inspect for damage in the springs, rollers, and spring caps. Replace any worn parts.

10. Re-assemble in reverse order taking care when re-installing the Alternator cover not to pinch any wires. If the cover will not re-install without force, check before any damage occurs.

11.One caution. These tend to get the skips and have difficulty with the one way clutch on the starter holding once they have been taken apart if the old parts are reused. They may not look that worn, but as a matter of course I would replace the entire part # 13193-1006 and part # 92026-112.

12.Also, if you presently have a follow-on rattle or growl once the bike has started take a good look at the starter motor gear, Part # 21167-002, and the pin on which it rotates. That gear and pin tends to wear the center bearing surface after only thirty or so years and then cocks under load and puts the starter clutch assembly in a bind causing it to skip or rattle. One problem looks like the other.

13.Use assembly lube when putting the starter gear back together with the pin.

14. Read this procedure from Red Line Cycle:
redlinecycle.com/Starter%20Clutch%20Tech.html
(It may show a blank page, but information is there).


15. A video on how to do this repair:

cool thanx. I think I'm just gona buy the whole unit new. thanx for the advice and instructions

I just bought a 1981 kz 1000 ltd k-1. Had starter clutch problem, bought rebuild kit from zi and worked for a while. Does anyone have a diagram of the assembly of the starter clutch and all parts including the plate, thruster washer pins, springs and damper? Would like to know how it actually operates in detail.

1981 KZ1000 LTD starter is shown at kawasaki.com as follows:




Lots of good info on kawasaki.com, including parts diagrams, part names, part numbers, models sharing same part, availability, etc. Here's a link for help with navigating the site and finding information.

Click > kzrider.com/index.php?option=com_kunena&...w&catid=13&id=376734

Good Fortune!

No eBay APP ID and/or Cert ID defined in Kunena configurationIf in need of a shop manual, would consider this one:



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Look in my signature for a pdf version of the Kawasaki service manual, it will cover the starter clutch for you bike.

Make sure when you are re-assembling everything that you torque down 3 allen head screws that hold the clutch to the rotor. I failed to do this when my starter clutch came loose last year and it came loose again and made an aweful rattling noise that can be heard here



That was my bike a 2 years ago... your probably doing better than i was then.
Also if those 2 allen head bolts are missing threads or look wore out, take them to fastenal to get Grade "8" replacements. For God's sake dont go to Menards or any place like that to get new bolts. They'll sheer off. Good luck man.

KT

damm it , I cant get the flywheel to come off. got the bolt but dont have a wrench to keep motor from turning over while turning bolt. any back yard sugestions?

Got a buddy with a 1/2" or 3/4" air impact wrench? That's the best way to break it loose. I suppose an electric impact wrench would work too.

Option number 1 Put the bike in first gear and have someone step on the rear brake.

Option number 2 put a screwdriver between the idler gear and starter clutch gear jamming it so it won't turn.

When tight, smack head of bolt with BFH. Which may jar it loose.
But don't miss the bolt head and hit the rotor (may ruin magnets).
Sometimes helps to place a ball bearing (correct size, please) between the bolt and end of crank shaft.
Could use a rubber strap wrench to hold the rotor while tightening the bolt.

Click here > www.kzrider.com/forum/5-chassis/457395-c...stercylinders#457395

Good Fortune!