"What's a thrust washer?" & other starter clutch??

So the starter clutch on my '79 KZ750 is occasionally making the tell tale marbly grinding sounds that these are famous for. I don't want to remove it entirely like I know some of you have. But I do want some advice before I decide to dive in and fix it myself or take it to a trusted friend.

So the manual says there's a "thrust washer" behind the flywheel. What is that?

I'd appreciate any tips/tricks for removing the flywheel and starter clutch. I've seen a couple of improvised flywheel holders (the giant screw driver wedged between the footpeg bolts looks right up my alley).

I understand the bolt holding the flywheel in is reverse threaded and I've got a "flywheel puller" (it basically just looks like a big bolt). How exactly do I use that?

So I've got my improvised flywheel holder, a starter clutch rebuild kit and a "flywheel puller". What else do I need?

Thrust washer is basically a thick washer/shim used to set clearance or preload on a part.
On a 900/1000 the starter clutch is behind stator/dyno cover on left front of motor,not sure on 750

Does any of this look familiar?

Yeah it's in basically the same spot on the 750.

So after I get to it and hold it steady, I remove the reverse threaded bolt on the flywheel. Then the manual just says to use the flywheel puller to remove the flywheel. The "flywheel puller" just appears to be a large bolt.

How exactly do I use that to remove the flywheel?

That was actually a picture for a 79 kz750 I found .
On the 900/1000 you can use a rear axle bolt and a ball bearing big enough to fit into end of crank without chewing up threads.
The bolt bottems out against the ball bearing then as you continue turning it pulls the flywheel off.
It might be easier to just get the liska tool to pull it off instead of trying to find the perfect ball bearing to use .

I'll look up the liska tool you mention.

What I have is something like this:

www.z1enterprises.com/images/parts/DSC05222.jpg

Actually it might be that exactly, just can't remember if I got it from Z1. Anybody know if I need a ball bearing or something? Or will this do the job?

Topper, fly wheel puller threads into the RH threads in the rotor and pushes against the end of the crankshaft that has the LH threads for the LH retension bolt



the thrust washer, note located between starter gear and flywheel



don't forget




or you WILL be doing it again.

And when you get the urge to check the starter before replacing the cover, well the bike, work area, cloths, etc. needed cleaning any way.

And for reference,



Good Luck,
Jim

That's really helpful Jim. Thanks!

Thats a cool guy to take apart his bike to help you. :lol:

Pulled my rotor and starter clutch today.

I'd seen many suggestions for improvising a flywheel holder, including Rainman's big screwdriver pictured above. But none of them to worked for me.

What did end up working was a strap wrench. I had to clean all the oil off the flywheel with a a little mineral spirits, but that did the trick.