1981 kz750e

KZB2 650 wrote: Go to Partzilla they have all the numbers and diagrams ..... Eds suggestion is just as good too after checking it out.

221B0620 (6mm by 20mm) Counter sunk screw
12046-1032 sprocket
13193-1012 clutch assembly
they have the nettle bearing........ rollers, pins springs etc listed ...... these come with the clutch assembly so that helps the final cost of it..........
92015-1555 clutch hub nut.....92022-1116 (2.3) plain washer (mine takes a spring washer its called)
92026-022 (2.5) thrust washer
92026-116 (5.5) thrust washer...................... pan gasket, o rings for the pan, ........... clutch housing gasket..... maybe clutch springs since you'll have it out and check the friction plates out...... adds up if you want to do it right.

Did you use a impact on the screws ? You might still be able to get em still with one or with the bit JR told about ? ...... I didn't even damage mine using one although they were really in there.

These are the exact part no you need....

Dan-kz wrote: I looked for the parts in the diagrams tell I went cross eyed but I could not find them nor do I know much about threads, pitch how to measure them. I did get a reply with a sweet part list and some good advice on clutch springs and plates.
By the way I love your bike picture! Dan in Toronto Canada

Thank you!!! I've worked hard on it, and also am having to replace the starter clutch, I feel your pain!!!

JR wrote:

I have never heard of a clutch nut? So when I find out what that is I,ll buy a new one

I think its the big 30mm nut in you pic above

Heres a good vid from youtube which I have bookmarked for when I need to tackle mine

What a PITA. I'm sorry you guys have to go through all that just for a starter.Good to know though. :whistle: There has to be a heavier set of springs that could be used. It wouldn't have helped in this case. The clutch block was broken.
Steve

Your bike looks like it has a soul of its own that's not a bad thing just caricature. Dan love it

cleaning up engine wile waiting for parts.

The small screw is part#221b0620 (6mmby 20mm
the other two I can not find part #s for(6mmby55mm)
The grabit tool worked well Thank You.


look at the roller this one a good spring and sitting down in it's proper place.

this spring is weak and not holding the roller in it's proper place to engage to start my Bike.

While you have it apart be sure to inspect the starter gear. They get ridges (see image below) If yours is worn you should replace it while you can easily do so. Ed

Look at Partzilla for 1981 KZ750e2 under oil pump/filter .......... ....... number 221.......part #221B0655 6 by 55 mm counter sunk screw.

At the min you need the 3 rollers, springs and pins ........ I got the whole clutch assembly new and Ed is right you Really should buy the starter sproket too!!! You won't get it at Zilla unless they recently got a few in though .......try Cheap Cycle Parts for that.

I looked at the starter clutch too see why it had failed.
The three springs are compressed and not holding the rollers in there proper location.
So then I removed the springs and rollers, one was actually compressed so that it had lapped over itself causing it to bind inside the hole it is inside of. When removing the spring I had to use pliers but the other two just simply pulled out with my fingers.
These springs are all light gage to allow the rollers the engage ,but more so to allow them to coast when the engine is running.
Someone had spoke about using heavier springs to avoid the daunting repair .
The problem with that is the rollers need to be able to coast and heavier springs would put more force on the rollers not allowing them back off or (float) wile the engine is running thus causing mechanical noise and undo wear to internal parts .
The end result would be a sooner rebuild for low.
Taking the damaged worn springs and rollers, I rebuilt the starter clutch to see if it would engage and it did a great job of grabbing and coasting.
As for my part list it is complete now thanks to KZB2 650 basically the more parts you can replace in the starter clutch eg-58T gear and so on. The better off you'll be do to the tight specs of this system. I,myself want to get it on the road .Not onto the side of the road so I'm getting all parts. Thinking I will get 25000 miles for a proper repair but it will take time and money. In the mean time I'll clean up the rest of the bike as best I can and be looking for more info on repairs from all fellow KZ riders.. Big thanks. to all on hear Dan in Toronto Canada.

I was suggesting maybe springs for a bigger bike. Yes they must coast, only when forced to lock by the starter do they not. I've never had problems with the springs.
Steve

I looked at the one from my bike and it is smooth,( could be used again )BUT for how long ?
A new one will replace it Thanks Ed for all your help !

So you have actually tried it with none of the problems I've anticipated.?