Starter clutch failing on my KZ750 H LTD

I can't remember having this problem on my Z1. Yeah, I've changed things now and then but the clutch has never failed like these. My rotor is old along with my spares, springs etc. so that's why I asked. Being buried in the engine, the springs could be getting hotter? All I know is all the electric starters I've worked on, that are chain driven act like this, 70's Honda's whatever.
Steve

thanks everyone! I was able to find a video on youtube on how to do it and thought I would share for future reference if anyone needs it!

Thanks for posting the video
this going to be very useful.
Bookmarked for future reference.

How I missed that I don't know and its been on there for a year..... maybe we don't need the gear puller and pusher after all Randombeat.......

The guy in the video keeps referring to Phillips-head screws. He is mistaken. Kawasaki has always used JIS (Japanese Industrial Standard) screws. They look very similar, but using a Phillips screwdriver on stuck or very tight JIS screws will lead to grief. That is why we all see so many buggared up screw heads. 650Ed has posted several times a good explanation with pics, and describes how to alter a Phillips bit to fit the screws properly. A proper bit is well worth the expense and effort.

Ok I know I'm gonna get grief for this but according to the "Clymer" manual it says you don't need to remove the circlip and gear at the 3 minute mark on the video and you can just tap the assembly (gear and bearing) out and back home both without removing it.

I have a factory manual too and it shows removing the gear (once its out and on the bench) with the special puller and putting it back on with the pusher after bottoming out the bearing in the housing. I know A few of you have done the job and would like to here from you if you've done it without removing the gear.

Maybe without removing the gear you might not get the bearing bottomed out? or will the bearing plate do that after its screwed down?

Guessing I could rig up a bearing driver made outta pvc and pull the gear the way the video shows and then rig up a strap and use the hole in the shaft to push the gear on but would rather not unless you need to. The video doesn't show him putting the gear back on and since its a press fit not sure on that and am thinking you would need to press it back on.

KZB2 650 wrote: How I missed that I don't know and its been on there for a year..... maybe we don't need the gear puller and pusher after all Randombeat.......

I'm with ya brother, wish he showed reinstallation...

I'm pretty surer the trick with the bolts will work for pulling it, not so sure about putting it back on, maybe a rubber mallet/brass hammer, or wood and hammer? I've heard several folks mention the PVC deal....

The PDF ed sent me doesn't mention how to put pull/replace the gear, and does say you don't absolutely have to remove it... Anyone who needs the PDF about replacing the starter clutch, pm me your email and I'll send it o ya...

Anyone have a good lead on the sprocket? Just got my starter clutch out tonight, nothing obviously damaged. Sprocket a little warn. I've got the springs pack ready to go in but reading this and seeing Ed's photo makes me want a sprocket. Only took a few hours to get it out, and that's pulling both wheels (they're getting new rubber.) I've gotten a lot of parts from Partzilla but they say the sprocket is obsolete. Prefer to skip the eBay if I can.

PS - use air tools!
Thanks,
-Paul

Check out the thread "Starter won't grab" on page 4 of the engine section for more info on the gear ......

And did you remove the gear in the question I have above before pulling the shaft ?

KZB2 650 asked me by PM:
"Was wondering If you could answer the question I have about removing the gear on the starter clutch shaft before I tear into it ...... Its near the end of the thread "Starter clutch failing on my KZ750" on the first page of the engine section. Thanks"
Yes I removed the gear. I remember thinking during reassembly that I hadn't needed to as the bearing didn't need much in the way of persuasion to fit into place. But I was being cautious not wanting to side load the bearing by driving on the end of the shaft.
I did the job with the engine still in the bike. IIRC, it wasn't much fun working up side down.
Good Luck
Bill

Thanks KZCSI and if we deside to remove this gear how did you put it back on ...... with a socket and a bolt in the threaded center of the shaft ..... or maybe a strap and the bolt in the shaft pushing it back on ...... don't think it would be tapped back on and I don't want to buy a gear pusher ...... thanks again for the help its for several of us.

Twilightoptics wrote: Anyone have a good lead on the sprocket? Just got my starter clutch out tonight, nothing obviously damaged. Sprocket a little warn. I've got the springs pack ready to go in but reading this and seeing Ed's photo makes me want a sprocket. Only took a few hours to get it out, and that's pulling both wheels (they're getting new rubber.) I've gotten a lot of parts from Partzilla but they say the sprocket is obsolete. Prefer to skip the eBay if I can.

PS - use air tools!
Thanks,
-Paul

I got mine from cheapcycleparts.com .. Believe a few others have lately also... Hope that helps