Starter woes: KZ650

'79 KZ650 B3

My starter's gone crazy.

Intermittently, it partially engages, then disengages. Real ugly sound when it does it; grinding, clanging, etc.

Reminds me of old Ford starters when the Bendix drive would go out.

I'm guessing it's the starter clutch?

If so, do you have to split the cases to fix it?

No, it´s actually the other way around, you have to remove the secondary shaft and starter clutch in order to split the cases.

Here´s a link to a write up I did on the subject (pdf):

KZ650/750 four starter clutch repair

It is even possible to do the repair with the engine still in the frame, several members here have done it that way.

Post edited by: OnkelB, at: 2008/03/02 15:15

Man, that is great!

Thank you very much.

OK, got her torn down. Here's what I need. On the diagram you put on page 1:

#14 gear is bad.

#10, #11, #12, the spring, roller, and plunger in the starter repair kit.

The one I need is A1.

I looked on Z1Enterprises.com, but don't see them. They also don't show an oil pan gasket.

Can anyone tell me where I can get those parts?

Thanks

seanof30306 wrote:

OK, got her torn down. Here's what I need. On the diagram you put on page 1:

#14 gear is bad.

#10, #11, #12, the spring, roller, and plunger in the starter repair kit.

The one I need is A1.

I looked on Z1Enterprises.com, but don't see them. They also don't show an oil pan gasket.

Can anyone tell me where I can get those parts?

Thanks

These guys probably have a used starter setup.

www.mcmart.com/mall/mc_kawa_part.htm

OnkelB wrote:

No, it´s actually the other way around, you have to remove the secondary shaft and starter clutch in order to split the cases.

I don't think so, to remove the crank you do, but not to split the case

Leastways that's the way it is on the 750 four motors, and I'm pretty sure the 650's are the same. The secondary shaft is in the bottom case half, so you have to have the motor right side up and remove the top case, then the crank and secondary shaft remain in the bottom case. If you want to split the case while the motor is upside down, then you have to remove the secondary shaft first.

And Z1 has lots of stuff that's not listed on the web site, and they can get lot's more. It's always worth giving them a call.

Post edited by: steell, at: 2008/03/06 23:23

steell wrote: The secondary shaft is in the bottom case half, so you have to have the motor right side up and remove the top case, then the crank and secondary shaft remain in the bottom case. If you want to split the case while the motor is upside down, then you have to remove the secondary shaft first.

That´s true, Steve, it can be done that way if the top end is already removed. Guess it´s a matter of preference - imo splitting the cases with the engine upside down is the easiest way as you´ll have to flip the engine over anyway, most of the crankase bolts are on the bottom. It just makes sense to me to remove the topend and top bolts, flip the engine over, remove the bottom bolts and lift the lower case off. Another benefit of the upside down way (with secondary shaft removed) is that you can split the cases without touching the topend in case you only need access to the transmission.

Post edited by: OnkelB, at: 2008/03/07 07:52

Check the prices over at Ron Ayers Motorsports and just type the Kaw part number in their search box. If you look at the part that is the "one way assembly", understand that it includes the rollers, pins, and springs.

I did one last year and have documented my experience a few times.

OnkelB wrote:

[
That´s true, Steve, it can be done that way if the top end is already removed. Guess it´s a matter of preference - imo splitting the cases with the engine upside down is the easiest way as you´ll have to flip the engine over anyway, most of the crankase bolts are on the bottom. It just makes sense to me to remove the topend and top bolts, flip the engine over, remove the bottom bolts and lift the lower case off. Another benefit of the upside down way (with secondary shaft removed) is that you can split the cases without touching the topend in case you only need access to the transmission.

Ahh, that's the difference then

I have done a couple of 750's, but both of those were for 810 and six speed conversions, so the top end was off anyway.

N0NB wrote:

Check the prices over at Ron Ayers Motorsports and just type the Kaw part number in their search box. If you look at the part that is the "one way assembly", understand that it includes the rollers, pins, and springs.

I did one last year and have documented my experience a few times.

Thanks for the lead. I didn't see the "one-way assembly", and the guy hadn't heard of it, so I just ordered 3 of each.

I also found the parts at cheapcycleparts.com, and their prices are a little better, but I kept getting an answering machine when I called them.

Partsnmore.com has a "starter clutch kit" with 3 of each that was 3.00 cheaper, but they have a 35.00 minimum order, and they didn't have the starter sprocket I need, too.

Post edited by: seanof30306, at: 2008/03/07 16:30