Time to replace starter clutch and Wiring

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05 Apr 2022 20:32 - 06 Apr 2022 07:12 #865016 by bvanzandt
This is my 1982 Kawasaki KZ650. I'd like to replace all the wiring completely, starter clutch, chain, timing kit, etc. Any recommendations or tips are greatly appreciated.
Last edit: 06 Apr 2022 07:12 by Street Fighter LTD.

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06 Apr 2022 15:45 #865054 by TexasKZ
Replied by TexasKZ on topic Time to replace starter clutch and Wiring
Buy some quality tools and a factory service manual.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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  • hardrockminer
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06 Apr 2022 16:26 #865058 by hardrockminer
Replied by hardrockminer on topic Time to replace starter clutch and Wiring
You will have to split the cases to rebuild the starter clutch and replace the cam chain.  Regarding the wiring...if you're having electrical issues you might need some work but if everything is OK then I would suggest sticking with what you've got.

I have several restored bikes along with a 2006 Goldwing with a sidecar. My wife has a 2019 Suzuki DR 650 for on and off road.

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06 Apr 2022 21:00 #865069 by woodyvale
Replied by woodyvale on topic Time to replace starter clutch and Wiring
Personally I would use the existing loom and just replace the earth leads and battery positive leads with new.
Also replace any dodgy looking connectors or frayed wires.
You can always go back into it once the bike is running. otherwise you might be chasing faults caused by the bike AND the new loom.

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07 Apr 2022 06:43 - 07 Apr 2022 06:58 #865077 by martin_csr
Replied by martin_csr on topic Time to replace starter clutch and Wiring
Do you have all of the electrical components? igniter, ignition coils, voltage regulator, etc.

CycleTerminal.com has stock type connectors & open barrel terminal pins.  Get an open barrel crimper >> the crimps are very strong. 
I already had a HF ratcheting crimper but the crimp dies were wrong, so I got an open barrel set.  Total cost was the same as getting the correct tool from CT or wherever.  CT has a nice set of term pin extractor tools, handy for removing terminal pins from the plastic connectors.
Z1Enterprises also has some of the stuff plus color wire.

 
Last edit: 07 Apr 2022 06:58 by martin_csr.

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08 Apr 2022 12:10 #865133 by azman857
Replied by azman857 on topic Time to replace starter clutch and Wiring
Get a starter clutch from a 01 - 05 ZR7.  It's a way better design and a drop in size. No mods needed.

I don't have a plan and I'm sticken' to it! '77 KZ 650 / 750 GPz custom project in progress
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  • ThatGPzGuy
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10 Apr 2022 06:08 #865200 by ThatGPzGuy
Replied by ThatGPzGuy on topic Time to replace starter clutch and Wiring

You will have to split the cases to rebuild the starter clutch and replace the cam chain.  Regarding the wiring...if you're having electrical issues you might need some work but if everything is OK then I would suggest sticking with what you've got.I don't 
I don't have a 650 but on my 750 I can get to the starter clutch by just turning the engine over. If you replace the cam chain then the cases will need to come apart but, unless there are a lot of miles on the engine you might not have to. 

Jim
North GA
2016 Yamaha FJR1300ES
1982 GPz750 R1
1974 Kawasaki H1
1976 Kawasaki KZ400
1979 Yamaha XS650 cafe'
2001 KZ1000P
2001 Yamaha YZ426
1981 Honda XR200 stroked in an '89 CR125 chassis
1965 Mustang
1967 Triumph GT6
1976 Bronco
"If you didn't build it, it's not really yours"

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