TOPIC:

I know this is beating a dead horse, but what starter clutches are compatible with the I have a 78 750b? I see the kz400 has the same part number. Any other starter clutches with different part numbers work? I replaced the pins, dowels, and springs but still have issues albeit a little better but still skips.

What motor oil are you using? Ed

I am using 10W-40.

what state is the engagement surface on the sprocket in? if it has ridges from the rollers you need to have it machined as these sprockets are no longer available. When I rebuilt my 750b engine I polished all the surfaces lightly to remove any sharp edges that the rollers could get caught on. I also turned the sprocket engagement surface down .002" to remove the ridges and the starter worked perfectly, it was slipping before.

I will remove it and take some photos. I know the starter clutch had some weird wear on it. I just got this bike and got it running the other day, but hate trying to kick start it. I was hoping to purchase another starter clutch to try.

nk140 wrote: I am using 10W-40.

That's fine, but what exact motor oil (not viscosity) are you using. There are 10w-40 oils that are fine and there are 10w-40 oils that are really bad for the bike. So what is the brand of the oil you are using and what is the exact type of oil within that brand? This is important since most brands offer different types of motor oil in the same weight. Ed

650ed wrote:

nk140 wrote: I am using 10W-40.

That's fine, but what exact motor oil (not viscosity) are you using. There are 10w-40 oils that are fine and there are 10w-40 oils that are really bad for the bike. So what is the brand of the oil you are using and what is the exact type of oil within that brand? This is important since most brands offer different types of motor oil in the same weight. Ed

I am using valvoline 10W-40 specifically for wet clutch applications. I have always used this stuff or castrol oil for my older bike with no issues.

How do you remove the starter clutch from the flywheel? The bolt heads are covered on mine. Is it installed upside down?

Can the Zephyr 750 starter clutch be adapted?

Well I think you may have found your problem right there. That top cover has spun. the rollers are supposed to be completely covered and the bolt heads exposed. the rollers could be racking and getting jammed up because of that. it should look like this. IIRC this sheet metal piece is formed over a plate and its supposed to be one unit. If it spun you will need to weld it or something to keep it in place, or get a new clutch. what does the sprag gear surface look like?

DoctoRot wrote: Well I think you may have found your problem right there. That top cover has spun. the rollers are supposed to be completely covered and the bolt heads exposed. the rollers could be racking and getting jammed up because of that. it should look like this. IIRC this sheet metal piece is formed over a plate and its supposed to be one unit. If it spun you will need to weld it or something to keep it in place, or get a new clutch. what does the sprag gear surface look like?

The sprag surface has some nice grooves. May need to have it machined or replaced. I did get the sprag off today. We had to really mess up the cover to get to the bolts. I will make it a kicker until I find a sprag.

nk140 wrote: How do you remove the starter clutch from the flywheel? The bolt heads are covered on mine. Is it installed upside down?

Your starter clutch looks like to have a crack in the roller ramp....