starter/flywheel

i have a starter issue going on. when i hit the starter switch the flywheel does not always spin the motor. i took the cover off and watched while pressing the starter switch and the fly wheel was spinning but only occasionally turning the motor and sometimes only partially. is there a reason for this such as a type of centrifugal clutch or else how do i fix this? i appreciate all help i can get. once i resolve this issue then i'll be off to another i may have. but one thing at a time.:S [img]

by the way i have an 82 kz1100 shaft

Could be the starter clutch. If you still have the cover off, try turning the large gear clockwise, it should turn fairly freely. Then try turning counter-clockwise, it should not turn at all. If it fails this test, or if there are crunchy sounds when it turns, or if the gear wobbles, then a close look at the starter clutch is in order.

Over Running Starter Clutch Repair On the Older, Bigger 4’S

1. When preparing to repair the starter over running clutch have a few items on hand:

A. New alternator cover gasket.
B. New springs (3).
C. New spring caps (3).
D. New rollers (3).

2. If possible, put the motorcycle on the center stand and tilt to the right to reduce the oil volume in the alternator cover.

3. Place an oil catch pan under the left side of the engine to collect what small amount of oil that will escape when the alternator cover is removed.

4. Remove the foot shifter lever, left foot peg assembly and the sprocket cover.

5. Some Kawasaki’s have socket head cap screws(Allen type) and others may have fasteners with a Phillips type. If the latter is there, a # 3 bit seems to work the best for removal.

6. Remove the alternator cover and take care with the three wires coming from the alternator stator. These are the voltage supply wires for the motorcycle. Rest the cover on some newspaper or rags to prevent damage.

7. The magnetic Rotor or flywheel will probably require a removal bolt or puller. NOTE, SOME ENGINES HAVE LEFT HAND THREADS ON THE ROTOR!!

8. The over running clutch is bolted to the back of the rotor with three Allen head fasteners.

9. Separate the rotor from the over running clutch and inspect for damage in the springs, rollers, and spring caps. Replace any worn parts.

10. Re-assemble in reverse order taking care when re-installing the Alternator cover not to pinch any wires. If the cover will not re-install without force, check before any damage occurs.

will check soon as i get a chance to get back to it this week, and get back to you to let you know how it turned out. thx for the advice.

is the bolt holding this onto the crank standard or reverse threads

never mind the last question i reasoned it out and got it loose. now i just need to get pulley to get the rotor off. i really do need to get a manual for this thing.