Starter jammed - 2003 kawasaki Z 1000

several reasons
the teeth on the ring gear were damaged from continuous grinding during pinion engagement or engagement of the starter when the engine is running causing a burring of the teeth that altered the mesh ability and jammed the ring gear and pinion
metal in the teeth of the ring gear that causes a jam in rotation
starter motor not engaging before rotating
wrong no of teeth on replacement starter pinion or starter motor

would first check all connections if they are not loose, start from battery terminal, tighten it up, fuse, switch and then starter motor.



your starter motor need check, bendix most probably jammed and hence the click. I would suggest tapping it few times should retract it to correct position and would allow you to start.



would suggest removing starter motor from the vehicle, clean it well, check brushes and check if electromagnet is correctly retracting.



hope this will help you (not with spelling and grammar...) - do not forget to vote...

OK...jammed up or down? jammed up... motor may be locked up. jammed down, the starter gear is likely over travelled and stuck. sounds like a trip to the dealership..sorry.

There could be several reasons for this problem, but sometimes it is in need of a simple cleaning. Remove the 3-4 nuts holding the starter assembly on the top of the engine. Normally you will use a 10mm socket and ratchet to remove them. Turn the starter over in your hand so that you are looking at the starter pulley. Inspect the starter rope and make sure it isn't jammed between the starter pulley and the housing. If it is jammed, grab the starter rope and starter pulley and rotate them both together clockwise until the rope becomes unjammed. If the rope isn't jammed, turn the starter pulley counter clockwise gently. It will probably spring back and draw in the rope. If it retracts the rope slowly, spray WD40 around the bolt in the center of the pulley and work the pulley back and forth until the pulley frees up. If it doesn't free up or this isn't the problem, get back with me and I'll try and walk you through the rest of the repair.

The starter only clicks.This is indication of faulty starter or starter solenoid jammed.Check the connection between starter to battery.Remove the connections and recheck.If still the same problem then see if the starter is proper or faulty.Measure the voltage of starter by meter.Its a 12 volt part.If the voltage is low then its faulty starter or if the solenoid is jammed then also starter needs to be replaced.Check out this possibilities.This will help.As you mentioned that battery is good and properly charged as per this, the starter or starter connections to the battery seems faulty.Clean the battery to starter connections with carb cleaner.It can be available at any local car garage or at auto part store. -------- Thanks.Helpmech.

That clicking sound is the starter solenoid, starter might be jam or gone bad, while some one hold key to start, hit starter if jam will start, if it don't starter will have to be replace.

NO,when the dual mass flywheel goes you will feel it.starter motor jamming is normally down to worn teeth/release spring.

check the battary make shore theres plenty of life in it , if that doesent work make shore the starter moter is not jamming, if the stater moter is jamming try to krank it over mannualy that will free the starter moter , and then it should turn over . if it does then your starter motor is the problem

if the starter is jammed, you can probably get it up on the center stand put it in top gear and **** the rear wheel back and fourth. that may do it. or jumping the starter itself may do it.

The spring on the starter motor helix is either stuck or broke, or the starter gear is jammed in the flywheel gear.

Take the cover off the starter motor and you can see the flywheel, starter gear, spring and helix shaft.

If its just stuck, free it up and spray some WD40 in there.

If the gear was jammed into the flywheel teeth then check for damage and wear. They are made from quite a soft metal and burrs can easily be filed and removed.

The "clunk" you are hearing is probably the starter solinoid. If you think its a more mechanical sound than that, it could be the starter taking up slack against a jammed gear.

If the engine runs file on a pull start, its unlikely to be a jammed gear/flywheel and more likely the spring is broke or the gear is stuck at the base of the helix.

If its none of those things and the clunk is the solinoid, then you will have to check to see if 12v is getting to the starter motor. If so, it might actually be the motor.

So, in order of likelyhood/checking:

1) spring stuck or broke
2) Gear jammed on helix
3) solonoid <-> motor electrics
4) gear jammed on flywheel

Its a good idea to keep in working - very sensible.