Question about 1991 kawasaki Zephyr 750

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How to change the primary chain on a kawasaki zepher 750 without removing engine ,i am replacing the starter motor clutch and noticed the chain was slack

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  • kawasaki Master
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Ull need a clymer manual-each bike is different-thats bottom end work and special tools r also needed

Posted on Sep 07, 2010

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1 Answer

How to replace the starter on a 2002 harley


Pretty entailed job. Not like a car.
You will need to remove the primary and possibly the clutch basket/ starter ring gear to access an internal fastener holding the starter to the inside of the inner primary.
Will probably need a primary cover gasket and a quart of synthetic (klotz 80-90) primary chain case lube.
While you're in there you should probably check & adjust primary chain tension and the Delrin shoe the chain rides on.
Completely drain the old primary lube, don't mix old with new, the thing only takes 18-22 ozs (so okay, maybe you need 1.3 qts).
Consider the different kW starters available and get the one that best suits your needs (is the motor built? high use? etc...) Terry components makes great components with WARRANTIES!!
Gasket $20-$25, klotz fluid $16-$20.
Starter drive clutch $35 to $100+.
Starter $380- $490 and up
Also jack-shaft assemblies, ring-gears, etc...$50, $80, $$$$$
Finally; if you have a large displacement or built motor you should have compression releases. Use them religiously.

Oct 08, 2014 | Motorcycles

1 Answer

How do i remove a 1982 kawasaki kz 1000 starter motor


Follow the specific instructions in the Factory Service Manual. Step 1 - Remove the heavy wire from the starter solenoid. Either end will suffice. Step 2 - Remove the chrome cover over the starter. Step 3 - remove the screws that hold the starter motor in place. Step 4 - Lift the starter motor out of the engine. NOTE: removing the carbs may make this step simpler. The "business" end of the starter should come out of the splined starter clutch gear. If you have trouble removing the starter from the clutch gear, you may need to remove the left side stator cover to gain access to the starter clutch and chain. The exploded parts diagram is available HERE Kawasaki Motorcycle Parts 1982 KZ1000 J2 STARTER MOTOR STARTER CLUTCH...

Aug 24, 2014 | kawasaki Csr 1000 Motorcycles

1 Answer

1988 Kawasaki VN 750 Vulcan how to replace the starter clutch


Hi, Anonymous for this scenario you will need your service, parts fiche, and owners manual if you can't find the best tool you ever bought for your Honda, despair not, for a mere zero $0 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need for viewing and printing please click on the blue links below. Good luck and have a wonderful day.
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Feb 19, 2014 | 1988 kawasaki VN 750 Vulcan

1 Answer

1987 Kawasaki VN 750 Vulcan will not turn over


Hi, Tomwalsh286 before testing any electrical component in the Starting Circuit it is "IMPERATIVE" that you have a fully charged battery of 12.5 volts or more and be able to pass a proper "LOAD" test if necessary, you may have a preliminary reading of 12.5 volts or more but little or zero amperage, the battery is faulty and must be replaced. AGM type batteries fall into this scenario more so than lead-acid batteries.
1. Ignition Switch not in the "ON" position.
2. Engine Run Switch in the "OFF" position.
3. Engine Run Switch is "FAULTY" or corroded.
4. Check the battery terminals for damage or corrosion check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter.
5. Bank angle sensor needs a reset or is faulty.
6. FOB battery low or dead.
7. Faulty ignition switch.
8. Faulty starter button.
9. Faulty kickstand, clutch, neutral safety switch.
10. Security alarm needs a reset.
11. Starter relay, solenoid, starter motor or circuit wiring faulty.
12. Starter armature or field coils have failed.
13. Main fuse or circuit breaker may be blown or faulty.
14. Faulty ignition relay.
15. The electric starter is working but starter clutch has failed.
16. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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May 16, 2012 | 1987 kawasaki VN 750 Vulcan

1 Answer

Kawasaki gpz 750 won't start and only makes a


hey bud, i know this might be a bit late but sounds like the starter chain tensioner has failed and the gears have vbeen stripped. dont try to start thebike. take the clutch casing off, and that chain and sprocket assembly infront of u is the offending part. google a guy called andy bennett for a manual chain tensioner. replace thes parts with zzr1100 parts as they are stronger. once youve researched and done all that. take the sump off and give it a bloody good clean. then re-assemble and away u go. u can do all this without taking the engine out the chassis. exhaust off, oil cooler off, radiator off. hope this helps. feel free to cantact me. kiltednutter (facebook)

Mar 01, 2012 | 1987 kawasaki GPz 1000 RX

1 Answer

How do I replace starter on 2002 sportster


First disconnect the battery cable. Then you'll have to pull the primary cover off the engine. Find the primary case drain plug underneath the rear of the primary case and remove it to drain the oil. Find the primary chain tensioner underneath the primary cover near the center and loosen the locknut. Turn the screw downwards to loosen the tension on the primary chain. Remove the left foot peg and take the "derby cover" off of the primary cover. Remove the spring and lock nut underneath the derby cover. Remove the bolts around the primary cover. As you gently pull the primary cover away from the engine, turn the clutch adjuster screw under the derby cover in a clockwise direction until the primary cover comes off. Remove the battery cable where it bolts onto the starter motor and the small single wire that plugs to the motor. Just above the clutch assembly there are two bolts. Remove these bolts and the starter will come off the engine. The bolts are different lengths. Make sure you mark which bolt goes where.

Good Luck
Steve

Sep 05, 2011 | Harley Davidson XL 883 Sportster...

1 Answer

How hard is to replace primary chain on a 1994 750 zepher


This is not an easy job and some special tools are needed. Normally with regular maint, these chains will last the life of the engine.

Jul 22, 2011 | 1991 kawasaki Zephyr 750

1 Answer

GPZ 500 - starter chain spins on cogs


First may I say I don't know for sure your bike model that well (In- line 4 cylinder or water cooled twin?) BUT I am very experienced with motorcycles ( I am a qualified motorcycle mechanic & have owned GPZ 550, Z650, ZIR-II ).
For starters Kwasaki have used two different methods of delivering drive from the starter motor to the engine. Gear driven & chain driven. The chain driven type ( like GPZ 900 R ) were equiped with a tensioner. If yours has a tensioner be sure to change it with a new one also.

Both of the styles of drives ( chain & gear ) incorporate what is called a starter clutch mechanism.

This is what allows drive from the starter motor to be applied only when the starter motor is activated & free wheel when the engine runs. It is a one way clutch mechanism.

I am explaining this because a verry common fault on all electric start bikes is the starter clutch. ( except Moto-Guzzi, BMW, Harley which use a car style starter with a sliding pinion ).

When the starter clutch is faulty it displays a very distinct symptom.

When the starter motor is activated, you will hear a "whizz" followed by a crunching noise rather reminicent of a chain jumping teeth on a sprocket.

If this is the case with your bike & is what is what led you to change the chain, plus is what your continueing problem is, I would suggest you check the starter clutch.

The starter clutch comprises of a drive gear(the one that the chian, or startor motor output shaft drives), 3 rollers, three springs with guide pins, & the housing plate for the rollers & springs with guides.

To effectivly repair a starter clutch it is necessary to replace the gear, the 3 rollers, the 3 springs, sometimes the housing plate if it is also worn (from the rollers moveing)

I am hopefull this may shed some light as to the cause of your problem.

If not please post a comment & I'll try to help you further.

Regards Andrew porrelli

Jan 13, 2010 | 1993 kawasaki GPZ 500 S - GPX 500 R

1 Answer

1990 Kawasaki ZXR 750 starter clutch not working


Hi, Rotis70 the starter clutch is a separate mechanical gear driven component that is activated by the starter motor, it engages the clutch pack gear or the flywheel gear to turn over the engine. It has an internal mechanism that allows the gear to turn in one "ONE DIRECTION" only and once the engine starts allows the gear to free spin with engine rotation. If the starter gear free spins in "BOTH DIRECTIONS" then the drive gear has failed, it might be serviceable on some models but usually needs to be replaced.
For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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Jan 02, 2010 | 1990 kawasaki ZXR 750

1 Answer

Benelli 900 sei


Dear Sir. The engine oil flows through the starter clutch which acts as a centrfugal oil filter. Sludge builds up and causes the starter clutch to slip.

It is possible to replace the Benelli 900 starter clutch without having to remove the engine.
It requires removing the clutch, then the side casing and gears. The sump needs to be removed...middle exhauster header pipes first. The lh engine cover and oil pump also needs to be removed. The primary drive shaft can then be removed from the RHS of the engine. the primary drive chain and satrer clutch assembly will now drop enough to enable the removal of the sprocket from the starter clutch (it is a bit tight and then the rest of the starter clutch will come out of the chain. Be aware that the oil pump drive connector is on the end of the primary drive shaft and care needs to be exercised. This is possible if due caution and care is taken. Assembly id basically reverse of above. Happy fixing.

Mar 31, 2009 | 1982 Benelli 900 Sei

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