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Yes I believe you are correct, that sun gear would have been pressed into that Housing, from what I see out there. I did a Mazda starter similar to yours not that long ago. The sun is pressed into that end housing.
Wouldn't you say that if the Sun was held in place that the drive force would be transferred to the output? As this Sun and Planets are just reduction gears for the high compression of the bigger twin cylinders. I wonder if it could be welded in place?
Not uncommon to upgrade to a reduction starter on a High compression street machine.

Yes, that is correct. If the sun gear were to be held in place the drive would be transferred to the output shaft. I dont know if it can be welded but i'll look into it. Can it be re-pressed back in?

What is the reduction starter upgrade you mention? I've never heard of it.

The upgrade I mentioned is for Street Machines and not Bikes. Just through it in, sorry if it confused you. Just that technology has changed for those old cars we like. So an upgrade is available.
If it could be welded, it would have to be in the correct position or biding of the gear set would occur. Repressing, well maybe if the outside of the Sun and the Inside of the End Housing were Knurled. Then a Locking agent such as The Red Stud and Bearing Mount From Lock-tite was applied.
If your town has a Rebuilder he might be able to source up the new End Housing with Sun Gear? We have 1 in town, and the guy Knows his stuff, been there a very long time.
Does that Starter Motor Have a Brand and # besides the Kawasaki? Like Nippon Denso or something?

I havent seen any name on it, nothing comes to mind.

There's no chance of a rebuilder here! It'd be cheaper buying a new motor if i were to post it away to be fixed as well.

Pressing i doubt will work, i dont see how the 2 would 'grip' or mate into each other permanently. I had hoped some kind of locking agent or glue may work but i think thats a tall order with the force it'll be put under.

Welding too will prob not work as the weld wouldn't be 'fine' enough as not to restrict things, it wold also have to be done on the inside of the sun gearing as you look down on it as there is no room between it & the outer casing. If it is welded inside the sun gears will then catch on the weld im sure.

Oh dear!!!

Ireland? Well never been i here its pretty scenic.
Whats the year and model of the 750 twin?

Yup, Ireland, good for Guinness & thats about it, but it is scenic! lol

Its a 1978 registered 1977 B2 model, the one with the field coil!, thats another story!

No eBay APP ID and/or Cert ID defined in Kunena configurationIt looks like #32 in the drawing would be the end nose housing, and I can only assume the Sun gear.
Part #16146-1008. Since you have it apart and have installed a kit, then this would be what you would need to finish it up.
or you could try the complete assy, #21163-1234



Here it is on Feebay: cgi.ebay.com/ebaymotors/Cover-Assy-Start...6-1008-/120133806182

Yeah, ranging between $90 & $120 new i see. Sweet!! lol

thank you v much for your help

That should get it working for you, then hopefully it should work for a long time.
Dink a couple of pints of Guinness for me!!

No eBay APP ID and/or Cert ID defined in Kunena configurationHang on, in this advert it shows the 2 pieces seperately! Now im more confused!

In the 1st pic there is a small piece of metal pictured inside the starter nose internal dust seal, i pictured it on page 1. This piece of metal must somehow lock that sun gear to the outer casing, when i stripped the motor it was lying loose in the nose!

Actually it shows it in the advert you have posted too!

]

cgi.ebay.com/ebaymotors/KAWASAKI-KZ750-7...r-Assy-/170454581585

That didn't show, but is it a Key, or Pin? That would lock it. Like I said i don't have one for comparison. I see something in the link, inside the circular piece it looks like a Lock Key.

I dont think its either a key OR pin, its a curved, thin piece of metal with 2 slight lugs at the top so it looks slightly like the letter T. How this fits in beats me but i reckon thats my problem!