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:
