Starter clutch failing on my KZ750 H LTD

KZB2 650 wrote: Awesome Random ....... The impact I have is a old sears model from I'd guess is from 1980-81 so I'm sure its not available anymore...... Correction I just punched up Ebay under Sears Impact driver" and they have one :laugh: The model number is 947641 and is .99 cents with 4 days left and 24.99 buy it now ...... 3 others watching it though. Maybe bid on it to get rid of the buy me and try to get it in 4 days ???

I saw a Vessel brand that's made like a screw driver with a built in impact that has a #3 JIS tip on it on Amazon and Ebay that gets good reviews (on Amazon) but that's all I know about it. It was around 20 bucks so that might be good too.

The clutch holder tool I got was 17 bucks shipped on Ebay and is a EBC brand .....pretty HD. Good luck.

Your the man!!!

For everyone else, especially those with a 650, here's a link I wish I had awhile ago, about 3/4 down the page, a step by step with parts list...
forums.kz650.info/index.php?topic=13260.0

Can you tell me what size sockerts are needed for the air tools? Is it 27&30MM?

I got my sprocket from cheapcycleparts.com a couple months ago, I used the supreceded part no to order it. Part no: 12046-1032

Hope that helps...

I got mine from cheapcycleparts.com

Part no 12046-1032

Do you happen to remember what size sockets, for which parts you needed the sockets? Clutch nut and shaft nut? 27 & 30 MM sockets?

Clutch nut is 30mm for sure ....... they have a c clip on my 650 so hoping someone can tell you the shaft size nut.... if you measure flat to flat I think it tells you right guys ?? Goggle it........ my 30mm nut measures right at 1 and 5/32 which is close to 1.160 and 30mm = 1.181 so I think that's how you do it? So if its just under 1 3/8 flat to flat it should be 27mm?

The hex allen to torque the 3 screws for the starter clutch are 6mm ....... I bought a 8mm over Ebay so I blew that one. Sure not many threads for where those go into to..... it is cast iron so should be some what tough but calls for 25 to 27 ft lbs in the Kawa manual. Think I'll go 25 with a lot of Loctite.

KZB2 650 wrote: Clutch nut is 30mm for sure ....... they have a c clip on my 650 so hoping someone can tell you the shaft size nut.... if you measure flat to flat I think it tells you right guys ?? Goggle it........ my 30mm nut measures right at 1 and 5/32 which is close to 1.160 and 30mm = 1.181 so I think that's how you do it? So if its just under 1 3/8 flat to flat it should be 27mm?

The hex allen to torque the 3 screws for the starter clutch are 6mm ....... I bought a 8mm over Ebay so I blew that one. Sure not many threads for where those go into to..... it is cast iron so should be some what tough but calls for 25 to 27 ft lbs in the Kawa manual. Think I'll go 25 with a lot of Loctite.

I have access to loctite 242, is there a big diff in it and 243?

Partzilla is showing the clutch nut as 20MM and the sec shaft nut as 18mm..

More research is in order lol

Metric bolt sizes always refer to the size of the thread, not the size of the head/nut.

Here's a small chart of the most common metric sizes including corresponding wrench sizes, Kawasaki seems to use a mix of DIN and JIS sizes, most aftermarket metric bolts will be DIN sizes:

www.boltdepot.com/fastener-information/b...-bolt-head-size.aspx

The 243 Loctite is a new formula and is suppose to hold up to oil better ...... is it any better probably not but I worry too much.

Also the 20mm they are showing I think is the inside dia........ trust me the clutch nut is 30mm.... I made the same mistake and ordered the 8mm hex allen for the 3 clutch hub screws cause that's what was listed for the size ....

Whups ....OnkelB's chart just seen it sounds like you need the 30 and 27mm socket after all.

O yah and the locking hub nut is not available anymore I e mailed Zilla a week ago and they told me they substitute and you should use the 92015-1555 nut in place of the 92019-015 now that's its not available ...Ed was right I ordered it on my first order and thought I got the wrong one when I seen it ...... they can't get the 92125-002 washer either so I'm gonna use my old one even though Ebay has a few.......

The nut is different looking but is the same depth and size .....it has a smashed indent on the outside near the end of the threads that is suppose to lock it...... I think I'm gonna Loctite it too.......cheap parts don't even list the original nut and none on Ebay or Z1 and a few others when I looked. Make sure you double check on the 750 vs 650 for the nut numbers.... I'm "guessing" they are the same.