TOPIC:

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.

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

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)

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.

Having the ZR starter clutch could be a selling point....for when the time comes to sell her...

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....