Starter gear slipping out of place

The starter gear on my 83 kz1100 has slipped out of place for the second time in the last couple of weeks. I'm wondering if there is some kind of shem that would take up the space between the end of the pin/ shaft that runs through the middle of the gear assembly and the recessed pocket in the cover that holds the pin in place. I'm not seeing anything like a spacer or shem in the schematics. Any ideas?

Best to post some pictures of your issue. That may clear up whats the problem.

Unless the casting is broken, I can't imagine how the pin could move and allow the gear to come out of alignment. If the stator cover, get another. :huh: If the engine case, good luck.

Sounds like you're missing a thrust washer on the starter gear shaft and it's allowing the gear to move outboard away from contact with the starter clutch gear on the crank.

Are you certain the rotor is not coming loose and allowing the starter clutch gear to walk instead?

The difference in measurement in the gear pin and the retaining pocket in the cover is 55 thousandths.

Is all good behind the starter gear?

Are you sure it isn't a starter clutch issue? This is more common. There are 3 Allen head bolts where the starter clutch hub bolts to the Rotor that back out. They need a few drops of Loctite and re-torquing. But the starter clutch springs and rollers are a common issue.

Thanks, that where I'm going next.I'm thinking you're right. I'm not even going to check, but instead simply replace with a fresh rebuild kit. They are pretty inexpensive and I'd like to eliminate problems and ride.

daveo wrote: Is all good behind the starter gear?

I replaced the starter with a new one last season, which is all that I have done down below in that area.