KZ 440 Starter Issue

Kano Kroil
Liquid Wrench
Magic Sauce - 50% acetone + 50% atf. Must be kept in an air tight container because the acetone flashes off pretty quickly.

I've been using Kano Kroil for quite a few years since an engineer friend recommended it. It works extremely well for me. Ed

Thanks fellas. My local Lowe's only had something called "Blaster" but it claims it's a penetrating oil. Hopefully this will help if I left it soak for days.

Hoping my next update with be with a removed starter!

I think that's probably PB Blaster.

I'm not a huge fan of the aerosolized/spray penetrants: they go *everywhere* (so there's a fair amount of waste) and they don't seem penetrate much better for being under pressure.

Something like Kroil can be dripped into place - less mess and it's more effective. Since I also have a can of PB Blaster, I'm thinking about capturing the liquid in a container and pouring it into an old-school oil can for easier application.

PB Blaster is better than syrup, but these days we sometimes have really limited choices. Kroil may only be available directly from the company, via the Internet.

I often spray small amounts of stuff into the cap and apply wth a pipe cleaner, small brush, or even toothpicks, depending on the job. Spray cans are a terrific way to waste a bunch of overpriced product.

I use liquid wrench. There was a recent video on youtube comparing the popular brands.

PB Blaster was definitely messy... Keeping those bolts soaked for a couple days while I'm waiting on the starter parts. Once they show up I'll go at that starter. Pretty confident I'll end up drilling those bolts out, they were damn tight. I may try the chisel and hammer method one of you fellas suggested too. Worse case I wreck the starter case and end up having to buy one of the new built ones.

Also reference the impact driver and 1/4 inch extension method... This is probably one of the methods I'll try as I progress from least destructive to more destructive. I'll definitely wear eye pro! Worse case if I loose the heads to the bolts I'm really hoping I'll be able to lift the starter free, leaving me two long bolt shanks to work out with some vice grips

One step forward, two steps back, fellas.

After a nice soaking of PB Blaster, I couldn't keep away. I gave one of the starter bolts a go and... She turned!

A moment later, I saw this... The damn bolt broke somewhere around the middle, leaving a large chunk in the block. Exactly what I didn't want....

I'm soaking the other bolt and giving it to tomorrow. I guess I'll need to drill out what's left of that other bolt to get the new starter in? I sure hope I can find replacement bolts for the starter motor.

Update! And it's good news!

Turns out I DIDNT break a bolt! The end of the bolt was corroded so I thought it had snapped, but I got the other bolt out and sure enough they are the same length. Whew!

PB Blaster and a solid few wacks on the bolts with a hammer and punch did it. They came out like it was from the factory after that!

Sure was nasty in the starter compartment. I can see how it ended up fried. I did a more involved bench test of the starter and she is definitely dead so I think I got at the problem. I'll be cleaning up that compartment for sure.

Now to rebuild the starter....

This can will last a lifetime, or actually will probably get passed down to your grandkids.



shop.advanceautoparts.com/p/permatex-ant...AvD_BwE&gclsrc=aw.ds

I actually have some of that in the shop, you better believe those starter bolts will be getting the treatment!

Right now I'm on the fence about rebuilding this starter or just buying a brand new one from Rick's Motorsports. It's 220 bucks, but will probably last as long as I ride the bike. I could still rebuild the old starter for the experience and sell it or keep it for another project. I'm reading the KZ 440 starters were prone to a magnet breakage that made them unrebuildable, which Rick's Motorsports claims they have fixed.