Dreaded KZ750 Start Clutch Gear

Correct. I searched for -003 and -001 came up. Close but sorry

If you polish the burrs of the engagement surfaces, and have the boss on the sprocket machined you will be good to go. I machined the boss down .003” and it has been perfect ever since. Any job shop machinist will be able to do this pretty easy

Thanks so much for the advice. The kit from Old Bike Barn is on the way

Here's some pics to illustrate what i mean. Polish the surfaces that the rollers slide on with 220 or a scrotch bright disk for a Rolloc.  www.3m.com/3M/en_US/p/d/b40064719/   , you don't have to go crazy just smooth any burrs over so the rollers don't get caught. Tell the machinist to turn the boss down till there are no wear marks. this should be very little, if they take off too much you might run into problems. Also tell them to use an arbor to hold the sprocket. If they try and grab the sprocket from the inside with the chuck jaws reversed they will damage the bearing that is in there. This stuff seems obvious but sometimes machinists just want to get the job done and don't think about the ramifications of how they do it.
 

can i send it to you and pay you? lol

Under normal circumstances I would say yes, however I'm in the middle of moving and setting up a new shop so all my tools are not setup. if you want to wait a few months I could make it happen.

sounds good. i just hate kicking this thing. thing is, sometimes the starter engages, sometimes it doesnt.

additionally, now I have backfiring on deceleration so need to figure that out. may be a cracked carb boot or the carbs themselves. always something.