kz750 twin starter clutch sprocket refinishing

The starter clutch sprocket on my KZ750 is worn with ripples where the roller engage. I cannot seem to find a replacement, unless I want to buy used cranks, fingers crossed only to find out they have the same issue. I assume the sprocket is hardened which means that the surface will have to be ground. IF i could find a place to do that for me, it would likely be prohibitively expensive. and thats a big "if" i called 12-15 shops locally to have a hardened bushing bored out not long ago and they all turned me down.
suggestions?

There should be photos here somewhere of new sprockets. They have tool marks as if the sprocket's starter-clutch surface was turned. If it's hardened, are there extra-hard tools that can cut it maybe?

EDIT: Nevermind. The photo was for a 750-four. In this thread.
www.kzrider.com/forum/2-engine/605365-kz...lutch-repair-failure

If your talking about the 750 four then the starter clutch assembly from the later 1999- 2003 ZR750 Zepher will bolt right in and is an improved trouble free design. Get on ebay and get a used assembly.
Nevermind just saw it's a twin 750

Yes it for a 1980 kz750 G (twin) I have been searching for a replacement with no luck. someone suggested i call a machine shop that grinds flywheels. I will look into that.

May I ask what the ripples in the surface cause? What is the symptom or sound that it makes?

its cause the rollers to slip and the starter spins too fast not engaging the motor. it sounds like a high pitch whine. very common on all the old KZs

No eBay APP ID and/or Cert ID defined in Kunena configuration

loudhvx wrote: There should be photos here somewhere of new sprockets. They have tool marks as if the sprocket's starter-clutch surface was turned. If it's hardened, are there extra-hard tools that can cut it maybe?

EDIT: Nevermind. The photo was for a 750-four. In this thread.
www.kzrider.com/forum/2-engine/605365-kz...lutch-repair-failure

This thread may be for a 750 4 banger, BUT the cause of the slippage is still the same, even though the 750 2 cylinder motor turns counterclockwise. In reading through the thread loudhvx posted, the problem is not the rough surface on the gear, rather the ramps are worn. It seems a new set of rollers helps for a bit, then it starts to slip again. If you have the gear surface ground, it will reduce the diameter more, and make things even worse (with the expense of grinding).
I do not know all of the dimensions, but a clockwise ramp assembly could possibly be retro fitted to turn the opposite direction by countersinking the mounting bolt holes on the other side on the rotor, and in effect reversing the locking direction by flipping over the roller ramps. (if this makes any sense to anyone). Possibly spacers installed to fill in the unused countersinks on the other side of the ramp assembly? Maybe welded in, then machine off the flat side.



What a deal! This used one is only $202.50
www.ebay.com/i/113057649512?chn=ps

Discontinued parts are going to need to be fabricated more and more, the more things are worn out.

Maybe this is a sign i should go back to kick only

DoctoRot wrote: Maybe this is a sign i should go back to kick only

Hardly. I have seen some of your fabrication skills, and this is nothing you can't fix my freind.