kz750g twin clanking when starting

starter clutch cks out fine. with cover off engine will start with no problem. with cover installed there is a very loud clanking sound when starter is engaged, sounds like metal to metal. I see no marks on inside of cover that is being hit. Motorcycle runs great after cranking. I have run out of ideas. can flywheel sprocket or starter sprocket or chain be problem.....help...ps sometimes when it does this I have tried to kickstart, it is very hard to kick start and kicks back like a banshee, Is this related to problem. Usually it kickstarts normally....

Inspect the flywheel/rotor closely, when the cover is off there is no load, when the cover is installed the magnets on the rotor are attracted to the stator causing a drag.

So, no noise with no cover, install cover and it makes noise.

The side aluminum cover , Not the flywheel,,,,does the aluminum cover have something to do with magnets and load? I thought it just held the oil in and increased load a little from oil pressure? I have a new starter clutch coming so I will install and rule out clutch.

The stator is bolted to the cover, when you bolt the cover on the stator fits inside the flywheel/rotor. The magnets on the flywheel/rotor act on the stator to produce electrical power, so they put a load on the flywheel.

It's a permanent magnet alternator so it produces power all the time it's turning.

no marks inside cover or stator...the only place that may be marked is side of engine wher starter chain may have hit,,,right on top of the big sprocket.....with everything installed and tourqed, the big sprocket has some play...Is this normal...also does starter sprocket install with long side first...that is how I read manual....but exploded view shows sprocket by itself with long side away from starter.....I'M CONFRUSSEDD!!!!!

The long side of the sprocket fits inside the starter clutch, that's what the rollers contact.

my starter gear spocket is correct,,I'm asking about the small sprocket on the starter....does the long side go toward the starter motor, or away from the starter..

If not already done, the parts diagrams at kawasaki.com might be helpful.

Here's a link toward navigating the site and finding information.
kzrider.com/index.php?option=com_kunena&...w&catid=13&id=376734

Good Fortune!

in the diagram the small sprocket (has one side flush one side portruding) looks like it should mount on starter shaft with flush side first,,,,,,,but in installation manual notes, it says portruding side mounts first....I'm still confused??? I'm trying to dot every I----to locate loud clank sound.

Are the Dowl locators on the case/ cover? there should be two, so the Stator and Rotor are aligned correctly. You sound to have an alignment issue, if with the cover off it all sounds normal.
Maybe try some Bluing to see where the contact is.

my cover fits perfectly,,,,i have installed new starter clutch...and it still clanks sometimes when i hit starter button. The large starter gear sprocket still has a little slack..the starter chain can be pushed at top of large sprocket and it will touch side of engine it appears to have worn into the metal some..i believe that is sound...I need solution..my small sprocket on starter motor is installed with flush side against starter motor as pictured.....(but in manual installation notes, it stated portuding side goes on first) My sprocket teeth are sharp, and chain seems a little loose. POSSIBLE SOLUTION:There is no shim pictured between large sprocket and engine maybe put one...File away the two areas on side of engine where chain hits. Try to locate both starter sprockets and new chain. any suggesions welcomed