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Starter clutch damper query-another prob
Moderators: KeithZ1R, chrisu, paul doran, Taffus
I've made a hideous blunder and assumed that Fatty's engine being a 79 had the later rotor assy. I've never had reason to take that cover off.
Pre 78 has the smaller rotor as below according to his Clymer. That said they also call the crank a camshaft so who knows.
It turns out that the following were amiss.
The stator screws (3No.) were all loose.
One was five turns un-done.
The outer thrust was grooved, scored and undersize at 0.90 mm. I guess standard new is 1.00mm
The damper (although three star (thickest variant)) had had the flange hacked off with a machete and measured up at 4.5 to 5.00 mm variously.
The actual gap (measured with blue tack) was 6.00mm (which is a ** two star damper)
The inner thrust bearing looked OK but it measured up as undersize and therefore should and will be replaced.
The springs in the clutch are suspect and are to be replaced.
The slack in the thrust washers accompanied with the missing flange on the damper was responsible for some of the issues but had allowed the back of the clutch housing to come into contact with the starter ring gear.
The starter ring gear may also be bent and is due to be checked for flat and bend.
It has wear marks on one half of one face and on the side of the teeth on the diametrically opposite side!
The clutch rollers had also been biting into the starter ring gear. Not on the bearing track but on their ends where they have been able to move up against the front face of the starter ring gear as it advances outward on the crank nose.
A new outer thrust should stop this i think.
The taper on the crank (no woodruff key) and taper in the rotor are perfect.
It also needs a nitrile 'O' ring on the intermediate idler gear shaft between the gear and the boss on the outer casing.
I put one on mine and it stopped the idler gear clanging against the outer casing when loaded with the stater motor.
Approximately 0.5mm cross section to the 'O' ring was best i found.
I took the starter motor out and bolted the outer cover on with the 'O' ring in place. put me finger through the starter hole and could still turn the intermediate idler gear with just the slightest resistance.
All in all a mixed bag but not beyond repair by any means.
Oppologies fatty i thought you had the later rotor that has the stator within it!
AL
Pre 78 has the smaller rotor as below according to his Clymer. That said they also call the crank a camshaft so who knows.
It turns out that the following were amiss.
The stator screws (3No.) were all loose.
One was five turns un-done.
The outer thrust was grooved, scored and undersize at 0.90 mm. I guess standard new is 1.00mm
The damper (although three star (thickest variant)) had had the flange hacked off with a machete and measured up at 4.5 to 5.00 mm variously.
The actual gap (measured with blue tack) was 6.00mm (which is a ** two star damper)
The inner thrust bearing looked OK but it measured up as undersize and therefore should and will be replaced.
The springs in the clutch are suspect and are to be replaced.
The slack in the thrust washers accompanied with the missing flange on the damper was responsible for some of the issues but had allowed the back of the clutch housing to come into contact with the starter ring gear.
The starter ring gear may also be bent and is due to be checked for flat and bend.
It has wear marks on one half of one face and on the side of the teeth on the diametrically opposite side!
The clutch rollers had also been biting into the starter ring gear. Not on the bearing track but on their ends where they have been able to move up against the front face of the starter ring gear as it advances outward on the crank nose.
A new outer thrust should stop this i think.
The taper on the crank (no woodruff key) and taper in the rotor are perfect.
It also needs a nitrile 'O' ring on the intermediate idler gear shaft between the gear and the boss on the outer casing.
I put one on mine and it stopped the idler gear clanging against the outer casing when loaded with the stater motor.
Approximately 0.5mm cross section to the 'O' ring was best i found.
I took the starter motor out and bolted the outer cover on with the 'O' ring in place. put me finger through the starter hole and could still turn the intermediate idler gear with just the slightest resistance.
All in all a mixed bag but not beyond repair by any means.
Oppologies fatty i thought you had the later rotor that has the stator within it!
AL
-
z1000Chris
- Regular Poster
- Posts: 28
- Joined: 20th Jul 2007
- Location: Watford,England
Yes Andy, they have broken up on my z1000 as well, it must be a common faultAndyZ1R wrote:Looks like i need to do mine again as the starter is still slipping and making horrible clanging noises when trying to start it. I think the 3 x bolts may be loose again.
Pigford what torque do you do your bolt up to? Because on mine it`s 95 ft 1b, and i can`t imagine a cable tie would hold it when it`s nearly breaking a decent size piece of wood in the rear wheel! But i`ll give it a go anyway.
What is the Kawasaki method of doing it? Is there a special tool? Also why does it need to be in 5th if i`m going the piece of wood/locking the rear wheel route? Is that the strongest gear?
Also anyone else experienced the slipping and really nasty metallic clanging sound? I need to get it sorted this week to try and race next Saturday, so any help is much appreciated!
p.s where are you racing this weekend, I,ll hopefully be at Shakey on Sat on my triple 
Thanks for your help again Al, and for putting up the pics and diagnosis on here. (And apologies to all for the hi-jack of this thread!)
Chris i was hoping to be at Shakey this Sat with the Zed, but as i won`t have the bits in time now to fix it that won`t happen. A real shame as i was hoping to meet up with you Triples guys and maybe have some Zed vs Triple drag action!
Oh well, there`s always the next one to aim for, what`s next on the calender after this one Chris? Will you be doing any at North Weald?
Chris i was hoping to be at Shakey this Sat with the Zed, but as i won`t have the bits in time now to fix it that won`t happen.
A real shame as i was hoping to meet up with you Triples guys and maybe have some Zed vs Triple drag action!
Oh well, there`s always the next one to aim for, what`s next on the calender after this one Chris? Will you be doing any at North Weald?
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