Starter Clutch AGAIN

I have a 1982 KZ1100 A2 with 16000 miles. I replaced the rollers, springs, and caps in my starter clutch 2 months ago. Worked fine til about a week ago, now sounds like it did before, box of rocks when you try to start it! Can anyone tell me the likely cause of this and what to replace to solve it? I don't want to have to rebuild clutch every other month! lol Thanks for the help

When you replaced yours did you use a longer or stiffer spring? I replaced my rock crusher with springs that were stiffer and a bigger outside diameter. The spring I put in don't set inside the pusher it sits on the rim of the pusher. My housing for the springs at the base was deformed from the old busted springs. I took and made little plugs that goes under the spring to prevent further damage. I used the original rollers . I have not had no problems since and I have cranked the motor probably a 1000 time since. I'll upload some pics in a few weeks to show you what I did

LovinMyKZ wrote: I have a 1982 KZ1100 A2 with 16000 miles. I replaced the rollers, springs, and caps in my starter clutch 2 months ago. Worked fine til about a week ago, now sounds like it did before, box of rocks when you try to start it! Can anyone tell me the likely cause of this and what to replace to solve it? I don't want to have to rebuild clutch every other month! lol Thanks for the help

Had same issues a few years ago, and determined to replace the whole starter clutch with a new one, since the roller-ways were worn. No more problem.

No eBay APP ID and/or Cert ID defined in Kunena configurationIf you didn't replace the starter gear that may the be problem. They develop ridges where the rollers engage them and that creates problems. The image below compares a used starter gear to a new one. If yours needs to be replaced the good news is that according to Kawasaki.com they are still an "Active" part (see diagram below), so any dealer can order it. However, it might be cheaper to find a new one on eBay (see example below). Ed