Welcome, Guest
Username: Password: Remember me
  • Page:
  • 1

TOPIC: Zephyr 750 starter clutch how-to and parts list?

Zephyr 750 starter clutch how-to and parts list? 19 Feb 2019 08:25 #798880

  • jbeebe1
  • jbeebe1's Avatar Topic Author
  • Offline
  • Member
  • Member
  • Posts: 140
  • Thank you received: 5
Hey everyone,

I have (among others) a 93 zr750 (zephyr) in the garage right now that is displaying the classic starter clutch symptoms. It skips and "clunks" 99.9% of the time while cranking and only briefly "catches" to rotate the engine once-in-a-while. I'm not worried about being able to fix it, i'm only worried about knowing what to fix! haha

1) Could I just buy a rebuild kit for $30 that contains the pins and springs and call it a day?

2) Can someone provide me a parts list of things to buy from Kawi?

3) any good write-ups around? I found a few threads and videos from different kz's but there were variations and i'm not quite sure what i'll have to do for the Zephyr.

I appreciate your guidance!
79 Honda 400 Hondamatic
79 Honda CB650
81 Honda CX500
81 Honda Passport C70
others coming in and out all the time!

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 19 Feb 2019 09:32 #798884

  • Pipes66
  • Pipes66's Avatar
  • Offline
  • Member
  • Member
  • Posts: 67
  • Thank you received: 0
In my recent experience,only when you’ve removed the s clutch assembly can you make the decision. Here’s how to approach it:
Check starter gear hasn’t gone smooth and shiny on the area that engages “in” the s clutch,if it has you’re definitely going to want to replace it ,£80 new.
Check s clutch “ramps” where the rollers slide up and down. Get a magnifying glass and make sure there’s no dents on it. If there’s any damage at all,buy a new one £106.
Repair kit is £25 but imho if you can’t guarantee the s clutch don’t risk it!

However,I’m sure plenty of good folk on here will advise you buy a 2nd hand complete zephyr s clutch off eb@y for £30 lol
1983 kz750 F1 Ltd Shaft US model

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 19 Feb 2019 10:40 #798887

  • jbeebe1
  • jbeebe1's Avatar Topic Author
  • Offline
  • Member
  • Member
  • Posts: 140
  • Thank you received: 5

Pipes66 wrote: In my recent experience,only when you’ve removed the s clutch assembly can you make the decision. Here’s how to approach it:
Check starter gear hasn’t gone smooth and shiny on the area that engages “in” the s clutch,if it has you’re definitely going to want to replace it ,£80 new.
Check s clutch “ramps” where the rollers slide up and down. Get a magnifying glass and make sure there’s no dents on it. If there’s any damage at all,buy a new one £106.
Repair kit is £25 but imho if you can’t guarantee the s clutch don’t risk it!

However,I’m sure plenty of good folk on here will advise you buy a 2nd hand complete zephyr s clutch off eb@y for £30 lol


good advice! I'm definitely not opposed to just buying it all before I even break into it. Or buying a used unit off ebay.

please keep the advice coming guys!
79 Honda 400 Hondamatic
79 Honda CB650
81 Honda CX500
81 Honda Passport C70
others coming in and out all the time!

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 20 Feb 2019 02:56 #798912

  • Pipes66
  • Pipes66's Avatar
  • Offline
  • Member
  • Member
  • Posts: 67
  • Thank you received: 0
Read my recent post”kz750 starting problem”there’s some v helpful pics of the starter gear.
Also you will read the success I have had swapping to a different oil,what oil are you using?
1983 kz750 F1 Ltd Shaft US model

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 20 Feb 2019 03:02 #798913

  • jbeebe1
  • jbeebe1's Avatar Topic Author
  • Offline
  • Member
  • Member
  • Posts: 140
  • Thank you received: 5

Pipes66 wrote: Read my recent post”kz750 starting problem”there’s some v helpful pics of the starter gear.
Also you will read the success I have had swapping to a different oil,what oil are you using?


Thanks, I'll check that thread out. Is the kz750 engine and gearbox the same as mine? Did you follow a write-up or manual to get the s. clutch assembly out?

As far as oil weight, I'm not sure. I just got the bike a week ago as a flip.
79 Honda 400 Hondamatic
79 Honda CB650
81 Honda CX500
81 Honda Passport C70
others coming in and out all the time!

Please Log in or Create an account to join the conversation.

Last edit: by jbeebe1.

Zephyr 750 starter clutch how-to and parts list? 20 Feb 2019 03:38 #798915

  • Pipes66
  • Pipes66's Avatar
  • Offline
  • Member
  • Member
  • Posts: 67
  • Thank you received: 0
From what I’ve read on here the zephyr s clutch is the same as my kz750,but better,not sure why.
If I were you I would get her running hot,drain the oil and the filter of oil,if it’s clean oil put the filter back in and try some 10w/40 semi synthetic. It could just be the wrong weight and a lot cheaper and waaaaaay easier than changing the s clutch. And you can always drain it into a clean container for re-use after you’ve changed the s clutch,if needs be.

You can do it with a manual but you’re gonna need some tools you may not have. For starters you will need a clutch holding tool,one of the mole grip types is fine,and you could do with an impact gun to get your clutch hub nut off easily. It can be done with a breaker bar and a length of tube over the end or a flywheel strap but it’s a faff. Oh,it’s soooooo much easier on a bike lift,invest now if you don’t own one,really,I bought a 2nd hand one for £200 and it’s my best tool.
You can follow the instructions in the manual,it’s pretty basic stuff,just a lot of work removing exhaust,footpegs,engine covers,clutch etc. Once you’ve got it all off and the sump is removed it’s fairly easy to slide the secondary shaft through to the rhs and jiggle the s clutch and gear out together. After you’ve done it you will realise it’s not hard, Just time consuming.

Top tip, there’s some staked screws on a retainer plate you will come across and have to remove,make sure you have the correct screwdriver bit to undo them. You usually get a selection in a decent socket set and from memory it’s a pz3 or something, you will know coz it fits like a glove and doesn’t ruin the screw,lol.
You need to remove the secondary shaft nut on the lhs under the blanking cover or certainly loosen it before removing the clutch assembly. If not that’s where the flywheel tool comes in.
1983 kz750 F1 Ltd Shaft US model

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 20 Feb 2019 07:41 #798931

  • 650ed
  • 650ed's Avatar
  • Offline
  • Member
  • Member
  • Posts: 14403
  • Thank you received: 2459
Change the oil. Ed
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 21 Feb 2019 04:15 #798979

  • jbeebe1
  • jbeebe1's Avatar Topic Author
  • Offline
  • Member
  • Member
  • Posts: 140
  • Thank you received: 5
Would anybody happen to have a digital copy of the FSM they could email me? It would be much appreciated.

Thanks for all the info guys, after doing some searching around the forum I can't believe how much the oil weight is affecting people's starter clutch.

I use rotella 15w-40 dino oil in all of my other old bikes. I'll try an oil change with the 10-40 semi-synthetic though.

I have a Yamaha 750 that I'm putting back together now, and once that's out of my garage in another week I'll be able to start working on the Zephyr. Pipes, thanks for the tips and the steps. I have air tools and some skill, but it would still be nice to have a manual for picture references.
79 Honda 400 Hondamatic
79 Honda CB650
81 Honda CX500
81 Honda Passport C70
others coming in and out all the time!

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 21 Feb 2019 04:46 #798981

  • Nessism
  • Nessism's Avatar
  • Offline
  • Sustaining Member
  • Sustaining Member
  • Posts: 4304
  • Thank you received: 1104
KZ/GPz manual here. Most engine elements are same as the Zephr
www.750turbo.com/manuals/GPz750_Base%20Manual.pdf

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 21 Feb 2019 04:55 #798983

  • Scirocco
  • Scirocco's Avatar
  • Offline
  • Expert Boarder
  • Expert Boarder
  • Never change a running system
  • Posts: 2021
  • Thank you received: 946
Attachments:

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 21 Feb 2019 04:57 #798984

  • jbeebe1
  • jbeebe1's Avatar Topic Author
  • Offline
  • Member
  • Member
  • Posts: 140
  • Thank you received: 5
Thanks guys!
79 Honda 400 Hondamatic
79 Honda CB650
81 Honda CX500
81 Honda Passport C70
others coming in and out all the time!

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 27 Feb 2019 17:06 #799352

  • jbeebe1
  • jbeebe1's Avatar Topic Author
  • Offline
  • Member
  • Member
  • Posts: 140
  • Thank you received: 5
I replaced the oil, but can't get it started to really cycle it through. Still won't ever "grab" to turn the engine over. Time to break it down!

What parts should I order from the dealer/online?
79 Honda 400 Hondamatic
79 Honda CB650
81 Honda CX500
81 Honda Passport C70
others coming in and out all the time!

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 28 Feb 2019 04:55 #799386

  • KZB2 650
  • KZB2 650's Avatar
  • Offline
  • Member
  • Member
  • Posts: 1387
  • Thank you received: 233
I used both the factory manual and a Clymer to figure things out....... the Haynes might show it well to. Go to Partzilla and punch in your bike and go over the parts break downs.
13193-1012 clutch assembly has pins, springs and rollers.
12046-1032 58T gear not avaliable so Ebay or search the hell outta parts ware houses. I found the stuff at Z power and cheap bike parts but that was years ago.
92046 needle bearing for the gear (optional)
oil pan gasket 11009-1983......... 3 o rings 92055a..... 1 - 671 o ring ...... for the pan.. a 92015-1555 clutch hub locking nut.... clutch housing gasket 11009-1985..... thinking this is the minimum you will need and double and triple check my part numbers.

Sure I'm forgetting some study the manual and you should figure it out.......... some have try'd replacing just the rollers and springs and failed. I replaced the housing and gear and have had good luck for 5 years and counting. You'll need a clutch holder tool off ebay and inch and foot lb wrenches maybe a impact for the clutch hub but a breaker bar might do it too. Think the nut was 30mm for the hub but yours could be diff. A hand impact with a #3 bit to get the oil pump off, blue loctite and the basic tools. Says you need a gear/bearing puller tool but the shaft tapped out gently for me and others.
1978 KZ650 b-2
700cc Wiseco kit 10 to 1.
1980 KZ750 cam, ape springs, stock clutch/ Barnett springs.
Vance and Hines Header w/ comp baffle and Ape pods, Dyna S and green coils, copper wires.
29MM smooth bores W/ 17.5 pilots, 0-6s and 117.5 main
16/42 gearing X ring chain and alum rear JT sprocket....

Please Log in or Create an account to join the conversation.

Last edit: by KZB2 650.

Zephyr 750 starter clutch how-to and parts list? 28 Feb 2019 07:16 #799390

  • jbeebe1
  • jbeebe1's Avatar Topic Author
  • Offline
  • Member
  • Member
  • Posts: 140
  • Thank you received: 5
Woo! That's just what I needed. Thanks for all the info. I just placed the order for it all on bikebandit. they had it all, including the sprocket, so I could order in one shot. I have all the necessary tools and the manuals that a previous poster linked to, so I should be good to go. I'll start the teardown next week and keep this thread up to date. If you think of anything else that I may need along the way, let me know.


SPROCKET,STARTER,58T 1 60.95
Part Number: 758487, 12046-1032

CLUTCH-ASSY-ONEWAY 1 112.95
Part Number: 768186, 13193-1062

1992 Kawasaki Zephyr 750 ZR750C STARTER MOTOR
BRG,NEEDLE,K253017 1 15.95
Part Number: 863669, 92046-056

1992 Kawasaki Zephyr 750 ZR750C STARTER MOTOR
O RING,90MM 1 8.10
Part Number: 851869, 671B2590

1992 Kawasaki Zephyr 750 ZR750C BREATHER BODY/OIL PAN
GASKET,OIL PAN 1 20.95
Part Number: 751400, 11009-1983

1992 Kawasaki Zephyr 750 ZR750C BREATHER BODY/OIL PAN
RING-O,19.5MM 3 16.41
Part Number: 864661, 92055-077

1992 Kawasaki Zephyr 750 ZR750C BREATHER BODY/OIL PAN
NUT,20MM 1 9.95
Part Number: 858079, 92015-1555

1992 Kawasaki Zephyr 750 ZR750C CLUTCH
GASKET,CLUTCH COVER 1 19.95
Part Number: 751401, 11009-1984

Subtotal: 265.21
79 Honda 400 Hondamatic
79 Honda CB650
81 Honda CX500
81 Honda Passport C70
others coming in and out all the time!

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 28 Feb 2019 10:33 #799399

  • KZB2 650
  • KZB2 650's Avatar
  • Offline
  • Member
  • Member
  • Posts: 1387
  • Thank you received: 233
damn Was a little to slow to tell you about the article "KZ650 starter clutch solution ZR7S part"..... maybe read that for a different and possibly better clutch...... but like I said maybe too slow to show you it now since you've already placed the order. Had to leave for a few hours and planned on updating when I got back. (couldn't remember the article to look for)
1978 KZ650 b-2
700cc Wiseco kit 10 to 1.
1980 KZ750 cam, ape springs, stock clutch/ Barnett springs.
Vance and Hines Header w/ comp baffle and Ape pods, Dyna S and green coils, copper wires.
29MM smooth bores W/ 17.5 pilots, 0-6s and 117.5 main
16/42 gearing X ring chain and alum rear JT sprocket....

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 28 Feb 2019 10:53 #799400

  • jbeebe1
  • jbeebe1's Avatar Topic Author
  • Offline
  • Member
  • Member
  • Posts: 140
  • Thank you received: 5

KZB2 650 wrote: damn Was a little to slow to tell you about the article "KZ650 starter clutch solution ZR7S part"..... maybe read that for a different and possibly better clutch...... but like I said maybe too slow to show you it now since you've already placed the order. Had to leave for a few hours and planned on updating when I got back. (couldn't remember the article to look for)


haha no problem, thanks for the thought. I won't have the bike forever (probably just for this coming season), so i'm not too worried about it lasting another 10 years.
79 Honda 400 Hondamatic
79 Honda CB650
81 Honda CX500
81 Honda Passport C70
others coming in and out all the time!

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 28 Feb 2019 21:56 #799433

  • azman857
  • azman857's Avatar
  • Offline
  • Sustaining Member
  • Sustaining Member
  • Posts: 312
  • Thank you received: 69
Having the ZR starter clutch could be a selling point....for when the time comes to sell her...
I don't have a plan and I'm sticken to it! '77 KZ750 custom project in progress

Please Log in or Create an account to join the conversation.

Zephyr 750 starter clutch how-to and parts list? 18 Mar 2019 15:15 #800592

  • jbeebe1
  • jbeebe1's Avatar Topic Author
  • Offline
  • Member
  • Member
  • Posts: 140
  • Thank you received: 5
Well I got the whole starter clutch replaced and the entire engine buttoned back up. I started it and it fired right up, but I heard a loud clunking coming from the bottom end. It's coming from the left side of the secondary shaft. Now that I think back I can remember needing to pound the secondary shaft in a little bit harder than I thought to get it to fully seat, so who knows what happened.

I guess it's time to tear the entire thing back apart.... :-(
79 Honda 400 Hondamatic
79 Honda CB650
81 Honda CX500
81 Honda Passport C70
others coming in and out all the time!

Please Log in or Create an account to join the conversation.

  • Page:
  • 1
Powered by Kunena Forum