Starter Clutch

Hey guys, been plagued by the starter clutch going bad. Very hard to start the 750 and sounds like rocks in my engine covers. I saw on Z1 that the ex500 (Ninja 500) is placed in the same group of parts that will fit? I found a kit on Ebay that I ordered for around 60$ for the EX500, 97-2001 I believe, that falls into the same time frames as on Z1. Any thoughts? Any others use a diff. model starter clutch kit for their kz's? I have a 1981 750LTD 4 cyl. Thanks ~

If you replace the secondary shaft with a ZR7 you can use that sprag type clutch instead of the 3 roller. It also mates better with the ZR7 oil pump which is a higher volume than the KZ.

Darftrusty shows what he did in his thread along with putting in a KZ550 6 speed trans.

kzrider.com/forum/11-projects/602462-kz750e-resto-mod?start=40

If you get in there and replace the rollers, springs, etc. take real close look at the starter clutch gear. They are prone to wear as shown below. Ed

You have lose 3 clutch bolts. Do not start engine! Enjoy rotor removal... :evil:
I had the problem on 80 KZ1000E and 81 KZ1000J. Rollers and springs were fine.

Hamman wrote: Hey guys, been plagued by the starter clutch going bad. Very hard to start the 750 and sounds like rocks in my engine covers. I saw on Z1 that the ex500 (Ninja 500) is placed in the same group of parts that will fit? I found a kit on Ebay that I ordered for around 60$ for the EX500, 97-2001 I believe, that falls into the same time frames as on Z1. Any thoughts? Any others use a diff. model starter clutch kit for their kz's? I have a 1981 750LTD 4 cyl. Thanks ~

I don't understand. Are you asking if the 750 and Z1 are the same?
Steve

I think he's refering to parts from Z1Enterprises.

No eBay APP ID and/or Cert ID defined in Kunena configurationHey guys. Yes I was referring to Z1Enterprise, not a ZR1. This is the kit we got. Says it fits an 87-09 EX500 and on Z1Enterprise part # ZKA22-004 shows that model and year along with the KZ750. Thanks guys!!!!

Looks good. In this case no rotor removal :whistle: . I suspect the springs become overheated being it is deep inside the engine. The "sprag{ type looks more robust.
Steve

Looks pretty decent....Hopefully will hold up..... I spent a lot more for original Kawasaki parts........ would consider like Ed said replacing the gear too but that's up to you.... have read a few have had to do it over again for not..... they recommend a new clutch basket nut and thrust washers too and of course a new pan gasket, o rings and clutch cover gasket. Be sure too blue locktite the 3 allens too at 25 ft lbs but your manual will point that out. Will be watching to see how it works out.

Every used starter clutch I've ever seen looked like Ed's "USED" photo, and they all worked fine.

I'd replace the rollers and springs with new OEM parts, not aftermarket. 90% chance everything will be fine thereafter. If the starter gear looks worse than the one Ed shows I'd replace that too. Or maybe try those ZR-7 parts.

Sweet, hopefully all works out! I'll take a good look over the starter gear and go with it from there. Doesn't look like too serious of a job. I do already have the needed gaskets and o-rings. Just waiting on the other goods! Going to throw on some new Carb. Intake boots too as mine are completely shot. Thanks guys for everything. I'll be sure to report back.

Update: Was able to replace the starter clutch assembly yesterday, actually wasn't too bad. Took me about 3 hours start to finish. The hardest part was cleaning off all the old nasty gasket material. Good thing I went in! The 3 allen screws that hold the assembly were totally stripped, not even keeping anything tight. Also the small gear on the clutch side had the retaining clip broken, luckily found the other half in the oil pan. Also the springs for the starter clutch were bent and one was way short, like a click pen spring. Also my 10mm oil pump bolt wasn't tight, it was finger loose. Now I gotta diagnose the no start