TOPIC:

I am in the process of putting a long neglected ZN1300 back together. I tried to start it today and it appears that the starter clutch is bad. I hit the starter button and I get maybe one or two engagements before the starter free spins.

So my question is do you think this is the starter clutch and how do I get this sucker out without the fancy Kawasaki tool. I tried a gear puller, but it just started to bend the edges of the stator. I also don't see anywhere I can bolt a puller to the starter clutch pack.

Thanks.

figured it out. The front axle is the same size as the starter clutch assembly. Just put a 10mm socket in as a spacer and tapped it with a hammer while slowly turning the bolt in.

Now i need to replace the part of the starter clutch that the 3 engagement lugs ride in. I found a crack in it where the spring and pusher go in. That explains why the starter just spins, can't get enough pressure to grab the gear.

Hello Sam:

Like you have found on yours, the clutch housing is prone to cracking from time to time.

You should be able to find one on Ebay for a reasonable price.

When you get the new one, make sure you Magna-Flux the housing to make sure it's serviceable, before installation. If you don't have the tools at home to do this, a local machine shop will be able to lend you a hand.

I just did mine this winter and the shop charged me $5.00 to inspect it.

As for the tool, I learn something new every day, I did not know the axle was the same size.

Bikemaster sells a universal 4-way tool that removes the rotor for about $25.00.

Regards.

Todd.

The pickings on ebay are a little light, but will keep my eyes open. I did find a new one for $75 so not going to pay too much for a used one.

$75.00 for a new one isn't too bad, that is close to what they were new when they were available from Kawasaki.

Like you say, pay accordingly when looking at a used one. Also review their return policy if the used one is cracked.

Given all of the mass this engine has, the starter clutch housing gets a workout with what it has to turn over.

T.