Question about 1991 kawasaki GPZ 500 S - GPX 500 R

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Starting the starter motorworks fine. behind the flywheel there is a sprocket which is connetected to sprocket at the end of the starter motor. when the start button is pushed the sprocket behind the flywheel should lock and turn the engine over which is not happening. the sprocket just spins freely.

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  • Anonymous Mar 13, 2014

    teeth on starter and flywheel looks great.

  • Anonymous Mar 13, 2014

    some times will catch and start.



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The sprocket behind the flywheel has a roller clutch. Very simple but difficult to describe, maybe you could google it. Its a common clutch arrangement used on many starters. They can often fill up with **** from the oil and the small rollers and springs inside don't move freely. If this is the problem then it only needs cleaning out and I usually give the springs a little stretch. ie. another millimeter is plenty. Sometimes a spring may be broken. The only way to find out whats really wrong is to take it apart  but you will need the correct puller to remove the flywheel. Its basically impossible to do this job without the right tools. 

Posted on Dec 17, 2008


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Hi there,

Same symptoms occur in vehicles from time to time. It was your 'hand turn the flywheel' that made me lean toward this diagnosis.

Although You have not supplied the make/model I can make a few assumptions. The symptoms you describe sound like a worn relay/solenoid supplying power to the starter motor.

When the contact surfaces are at the end of their usable life, less and less of the 'cold cranking amps' get past them. So instead of freely flowing to the starter, the power is bottlenecked.

Check what ever mechanism your generator employs to provide starting power.

If you found this to be useful, please take a moment to rate.

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The other thing the starter has to do is move it's gear forward about 1/2-1" to engage the flywheel gear of the engine.

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when you change a sprocket, you change the chain as this will lead to premature sprocket failure

Dec 31, 2008 | 1991 kawasaki GPZ 500 S - GPX 500 R

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