starter clutch assembly woes

[mysterious_rider]

hello dudes, recently did a gearbox rebuild on the zzr600 e3 95' and I must have misplaced a washer on the starter clutch, so it's been casually wearing through the backplate a bit and scratched it up (causing a nasty whine).

Thing is, part Isn't listed on any microfiche.

part worn is 16085 the sprocket bit. That should sit on a washer, then hit the crank lip and all hold tight once bolted, but it just sits on the flat of the crank, and touching the inner casing.

Does anyone know where to get this washer? Its got to be almost a cm wide... And stepped.

https://www.kawasakioriginalparts.com/kawasaki_motorcycle_parts_selection_pfk.php?block_01=E1840&block_02=99917-1566&block_03=MC&year01=1995&ca=GB
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KAWASAKIIIII

[MCN]

If you can't find a used one from bumtree or egay you may have to bite the bullet and ask for an engineer to spin a one off for you.
Maybe some lathery artisan will do it for a B/job or a pint of rum on here if you hang around.

I use Draganfly for my BSAs (hee-haw to do with this bike of yours) but sometimes their website shows a part number but the number is not in the parts list. You have to punch the number off the dwg into the search and it often returns the detail.
Possibly email those monkey on that site and ask them what the craic is?

[mysterious_rider]

cheers! managed to split one of the old worn gearboxes i had and found some thatll work. put it together and it seems ok! put it together with sealant so waiting on that to dry.
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KAWASAKIIIII

[mysterious_rider]

right, not meant to have a spacer, cos otherwise it locks the sprocket starter to the crank, and drags starter motor around constantly (very loud awful sound).

I refitted without spacer, so it can free wheel, but it will still drop back a few mm and hit the casing... My guess is its weak clutch roller/springs that let it drop in the first place.

If you tip the magneto and sprocket housing upside down, is it meant to fall out? I know they lock turning one way, and release the other, but static it should hold right? cos mine doesnt.
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KAWASAKIIIII

[mysterious_rider]

bumpppp
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KAWASAKIIIII

[Pete.]

[Pete.]

[mysterious_rider]

no it is smooth and good. what i meant is if you take the assembly out and turn it upside down will the springs and rollers hold the assembly in? cos in the engine it falls out (still turns over fine) but goes too far in and rubs tje sprocket face against the inner crankcase. cant spacer it as itll lock it onto the crank.

only idea is the rollers and springs need renewing.
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KAWASAKIIIII

[Pete.]

You're not making this easy to diagnose.

Let's get things straight - if you build the starter clutch onto the rotor and fix the rotor onto the taper with no spacer, then the starter clutch works fine but the gearhweel wheel rubs on the casing. If you add the spacer then the wheel locks because it's sandwiched between the rotor and the crank.

Is that right?
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a.k.a 'Geri'

132.9mph off and walked away. Gear is good, gear is good, gear is very very good

[mysterious_rider]

correct but there is not meant to be a spacer. microfiche dont show one. i can fit it as is fine, but the sprocket falls back a cm and hits the casing. i can make a pic when im home. so hard to explain
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KAWASAKIIIII

[mysterious_rider]

i since fitted biro springs and it improved a tad, the screaming it made was quieter... but still there. it seems to 'let go' of the starter sprocket and push it out of the rollers a tad and into the crankcase. it all works fine but the noise is horrid, and its visually worn the casing down. the casing protrudes slightly from centre crank.

whole new starter clutch needed then?
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KAWASAKIIIII