1983 kz750 Starter clutch ??

Hello, I am new to forum and look forward to learning, and helping as much as my experience will allow. Approximately a month ago I purchased this bike from the 2nd owner that had taken exceptional care of it, because it was making a funny noise at the engine level he had difficulties finding a buyer, until I came along...Either good for me or bad...lol. The problem with the bike appears to be in the starter clutch, after much time on the net and filling through several forums here, i am confident it is a repair I can handle. But, i do have one question to start with, concerning this procedure. How much play should there be in the idle gear that resides between the starter and and the starter clutch? This gear appears to ride on it own inpendant shaft. It has no up and down play, but considerable side to side play. I have not been able to find any mention of it, and want to make sure it is within reason before I close the engine back up...Thanks

The idler shaft floats on all mine too so nothing to worry about -I don't think..

The question for me being is it the starter gear boss, the rollers or the springs or all three. This was discussed quite recently here.

We like pictures here This was from my 550.

Mine was the same way had more than I wanted .......didn't measure but am guessing .010 at least ...... the 2 spacers on each side were not avaliable anywhere and am not sure they would have helped any way.

Thanks for the response, The play seems a bit much to me, but since it is a idler item it wouldn't need tight tolerances. As for the exact problem with my starter clutch, not sure yet. I removed the basket cover and the oil pan, halted my work when I seen the volume of play in the idler sprocket. Will be finishing it up tomorrow and will get some pics. Now that I know there is a community of KZ owners, I am encouraged to show pics of my whole bike, but with the engine out, it wouldn't look so good...")

When examining your starter clutch be sure to look at the starter gear. They can get ridges squooshed into them, and that can make the starter clutch slip. Here's a comparison of a new and old gear. Ed

Well now i am really confused, I try to stay away from that state as much as possible. I finally got to it today, However, after removing the starter clutch, it would seem there is nothing wrong with it. I haven't completely disassembled it yet, but from first impressions it seems as it should. I don't see visible cracks in the outer casing and the lobs appear to move as they should. As for further dis assembly, I will need help, if the allen bolts need to be removed I am in trouble because they are in solid and would be afraid of rounding them out. here are some pics, please let me know if I am jumping the gun on its condition. The bike was making noise just like the same bikes did in approximately 5 YouTube videos, they all said it was the starter clutch. Thanks for any help

That starter gear looks worn to me. I would replace it along with the springs and rollers so you don't need to pull everything apart again if it doesn't work. Please see my earlier reply that compares a new one to a used one. If you can't get those screws out try soaking them with Kroil for 2 or 3 days; then try again. If you still cannot get them out ask a machinist to help you. Ed

I measured mine with 0.02mm verniers and couldn't see any difference, but it is about surface finish too I guess.

I think a 30-50k motor plus a short spell with 12:1 yoshimura pistons just hammered it to death, on this I've picked up a a virtually new starter gear from an ex250 that fits the 550

Spot the difference here for the 550 parts:

What Ed and Tyrell said ( the sprocket and rollers are chattered up) and don't worry about the 6mm allens ....... if your just replacing the springs, rollers and pins (do all three you will feel a difference) you don't need to remove them....... only if you are replacing the whole assembly .......... I did even though I had no cracks in mine either.

Thank you gentlemen. Ed I am going to replace the starter gear, in the sunlight I can see the machining lines, but otherwise it is an example of a warn part just like you showed in your previous post. Also, already have plans to take it to the shop tomorrow as I don't have the patience to wait the penetrating oil time. I will just purchase it all new as the bike is in fantastic shape, and I don't want to fuss around in side it again. Just rather ride it...lol. This is probably not a good tell tale but I did run my finger around the rollers and they did chatter more than I would have expected. Again thanks for your help. Will post pics of her when I get her back together . Tim

The wear on the starter gear boss is one of those things that pictures don't really capture, but just the feel of it with your fingertips is more telling.

strangely enough, the one in the above pic looks pretty smooth and polished but was slipping bad -for a longtime. The other two are much 'notchier' but were not slipping.

Spot the difference between the two...oil feed holes. Did kawasaki revise this later to increase oiling?

Mine was cracked on the inside edge, not visible until I pulled the 3 Allen's and pulled everything apart... Might be worth checking if you can get ahold of an impact driver to get them out? I just shot all 3 with PB blaster and let them sit overnight, then was able to get all 3 oiut with a normal 3/8 socket wtrench and 6mm Allen head socket.. Just don't forget to locktight them when re installing....