78 kz650c2 starting issue?

Gentlemen,

So I have been working on my build for about 6 months now. Here is some back round.

78kz650c2
dyna S coils
Shorai battery (brand new)
re-wired so all connections are good

Issue:

We all know that these are cold hearted bikes and are a pain to start cold. I do not have use of my kick since i have installed rear sets. Yesterday while attempting to start I got the usual odd noises KZ's dump out. Then all of the sudden it seemed like the starter motor stays engaged for a good 3-5 seconds AFTER I release the start button.

What I have done to remedy so far:
swapped out the starter solenoid.
swapped out the starter motor.
took apart the start switch and cleaned it out.
inspected the gears on the starter motor.

Each time I swapped something out I attempted a restart and the same thing happens. The starter motor seems to stay engaged.

The motor is attempting to turn over but needs a little help (starter fluid).

Any ideas? Any other info, pics, video you need let me know.


Thanks!

Marc

What weight and type of engine oil being used? Most riders have good results with Shell Rotella T-6 oil. I suspect the over running clutch starter mechanism is hanging up(possibly a burr or two on the part that engages the starter motor).

Mine20 wrote: We all know that these are cold hearted bikes and are a pain to start cold.

I somewhat dissagree with this statement... Yes they are deffinately a cold-blooded animal stemming from the air cooling technology of thier time, but all KZs I have come across and fine tuned, start instantly with but a 1-2 second click of the starter.

I do not have use of my kick since i have installed rear sets.

Bummer :S I love kickers.

Yesterday while attempting to start I got the usual odd noises KZ's dump out.

? Oh... you mean the usual digesting nails kinda sounds - gotcha :lol:

Then all of the sudden it seemed like the starter motor stays engaged for a good 3-5 seconds AFTER I release the start button.

Yeah not good

What I have done to remedy so far:
swapped out the starter solenoid.
swapped out the starter motor.
took apart the start switch and cleaned it out.
inspected the gears on the starter motor.

Its most likely as MFolks suggested, a problem with the starter clutch mechanism, and parts replacement will most likely be in order. Dissasemble and inspect

The motor is attempting to turn over but needs a little help (starter fluid).

You shouldnt need to use anything extra to start your bike if its tuned up properly. Nice clean carburetors in wel tuned and synced state with a reasonably good compression motor will start easily even with a slow turning starter. I suspect a go thru of the maintenence chapter of your manual is on order - a thorough tune-up.

Cheers.

Oil being used in 10w40 Maxima racing oil.

Prior to changing it from stock it started right up without a problem. Things that were changed are:

Pods
4-1 exhaust no muffler
I rejetted but kept dumping fuel from the bowls. So I went and put the old jets back in. This is when it started again with starter fluid. Once it warmed up it started on it's own without issue.

I have done the usual maint suggestions here and on Kzinfo.com. I have not sync'd the carbs yet I am planning on I picked up an old school mercury sync tool.

I did inspect the starter clutch mechanism and it seemed fine. Prior to yesterday it was not making the odd noise after hitting the start button.

Heres a video.

Thinking it's the starter clutch. . .