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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
Karma :

PostPosted: 00:46 - 22 May 2016    Post subject: Reply with quote

I finally got around to replacing the starter clutch.

Sump Off

https://i491.photobucket.com/albums/rr279/bladeblaster/1_zpsyacsigmf.jpg

Oil Pump Out

https://i491.photobucket.com/albums/rr279/bladeblaster/11_zpspihq5jmw.jpg

Lower Case Off

https://i491.photobucket.com/albums/rr279/bladeblaster/111_zps5rygqnlo.jpg

Old Starter Clutch Out

https://i491.photobucket.com/albums/rr279/bladeblaster/1111_zpsbc4rfunj.jpg

The Old Starter Clutch Next To The New Assembled One

https://i491.photobucket.com/albums/rr279/bladeblaster/11111_zpswds5tjo3.jpg

Bottom Case Back On, very fiddly, hopefully everything is back tother properly!!

https://i491.photobucket.com/albums/rr279/bladeblaster/111111_zpsp3u7ujsp.jpg

The rest of the covers that had to come off (all of them) will go back on tomorrow with new gaskets. Ordered new seals for the oil pump as some were a bit shoddy, so that will be a job for the bank holiday weekend.
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chickenstrip
Super Spammer



Joined: 06 Dec 2013
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PostPosted: 08:47 - 22 May 2016    Post subject: Reply with quote

Dumbski question: you mention the starter clutches have a tendency to stick, what causes this? Some kind of wear?
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
Karma :

PostPosted: 10:58 - 22 May 2016    Post subject: Reply with quote

chickenstrip wrote:
Dumbski question: you mention the starter clutches have a tendency to stick, what causes this? Some kind of wear?


I think the springs loose their spring, and the rollers get worn
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
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PostPosted: 20:04 - 06 Jun 2016    Post subject: Reply with quote

Bit of an update.

Whoever painted the engine casings decided it was a good idea to also paint the gasket faces and put it back together with paper gaskets and tacky paint. Evil or Very Mad

So after many hours of scraping, and re-dressing the gasket faces are now as they should be.

https://i491.photobucket.com/albums/rr279/bladeblaster/44444_zpsuvwsfkmb.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/444_zpsrvp6zvol.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/13315383_10153636279259013_2910304170885738930_n_zpsg8jthpvv.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/4444_zpshnppgcpf.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/3_zpss14izx3o.jpg

A blob of silicon sealant on the casing split line

https://i491.photobucket.com/albums/rr279/bladeblaster/33_zpsvqddthc2.jpg

A proper gasket

https://i491.photobucket.com/albums/rr279/bladeblaster/333_zpsh7joxfep.jpg

Clutch case back on

https://i491.photobucket.com/albums/rr279/bladeblaster/33333_zpswno3zrbl.jpg
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
Karma :

PostPosted: 20:12 - 06 Jun 2016    Post subject: Reply with quote

Sump hasn't been off for a while. That's not metal in the filter its congealed rubber from perished seals.

https://i491.photobucket.com/albums/rr279/bladeblaster/2222222_zpsh7ox5lux.jpg

Cleaned up sump

https://i491.photobucket.com/albums/rr279/bladeblaster/222222_zpsqpfmjcom.jpg

Old seal

https://i491.photobucket.com/albums/rr279/bladeblaster/55555_zpsvn4eiels.jpg

New seals


https://i491.photobucket.com/albums/rr279/bladeblaster/222_zpseyp7sjty.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/22222_zpsid05exsj.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/2222_zpstoogpzyo.jpg
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af1
Borekit Bruiser



Joined: 09 Mar 2016
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PostPosted: 20:44 - 06 Jun 2016    Post subject: Reply with quote

Nice write up . Kawasaki always engineered their bikes so nicely.
Top work....
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
Karma :

PostPosted: 15:50 - 09 Jun 2016    Post subject: Reply with quote

Thanks.

Oil pump and gubbins back in

https://i491.photobucket.com/albums/rr279/bladeblaster/13412175_10153658608069013_6597341344292848603_o_zpsylpmbs1e.jpg

Sump back on

https://i491.photobucket.com/albums/rr279/bladeblaster/13419235_10153658607114013_5764830983756937324_n_zpszrtreghq.jpg

Rocker cover off to do valve clearances

https://i491.photobucket.com/albums/rr279/bladeblaster/13336084_10153658500854013_4243611844591234211_n_zpsgc9ro22f.jpg
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
Karma :

PostPosted: 22:40 - 03 Jul 2016    Post subject: Reply with quote

Valve Clearances done

https://i491.photobucket.com/albums/rr279/bladeblaster/00_zpsdidlt2yy.jpg

New seals

https://i491.photobucket.com/albums/rr279/bladeblaster/000_zpse0avsowc.jpg

Rest of the engine covers back on with new gaskets and seals

https://i491.photobucket.com/albums/rr279/bladeblaster/0000_zpse83qlxhx.jpg


https://i491.photobucket.com/albums/rr279/bladeblaster/00000_zps086cfmkt.jpg

https://i491.photobucket.com/albums/rr279/bladeblaster/000000_zpstr5asl1q.jpg

engine back in frame

https://i491.photobucket.com/albums/rr279/bladeblaster/0_zpslmz0q3fs.jpg

Now I just have to remember how everything was connected up Laughing
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bladeblaster
Trackday Trickster



Joined: 19 Jan 2015
Karma :

PostPosted: 22:38 - 12 Jul 2016    Post subject: Reply with quote

exhaust back on, which was much harder than it should have been, and I have no idea why. Bit of a bastard to get everything lined up.

https://i491.photobucket.com/albums/rr279/bladeblaster/12345_zpsqo153x7r.jpg

Sub frame and oil cooler back on (temporarily at least)

https://i491.photobucket.com/albums/rr279/bladeblaster/123456_zpslsrhpzob.jpg

Then had to take that back off, because its almost impossible to put the feed pipe from the rad to water pump back with it fixed in place. In addition to that the rad has to be located on the sub frame then the whole thing swung up into position, otherwise the rad won't locate properly. Rolling Eyes

All back together

https://i491.photobucket.com/albums/rr279/bladeblaster/1234567_zpsqvftb8hh.jpg

Front sprocket cover and hydraulic clutch cylinder back on, electrics all connected back up, with the exception of the starter motor because I have lost the nut.

https://i491.photobucket.com/albums/rr279/bladeblaster/1234_zps3aylify3.jpg

Then next step is reconnect the starter motor, air box back in, then fill her up with oil and coolant, and then the moment of truth. Should be done this weekend.
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Old Thread Alert!

There is a gap of 343 days between these two posts...

pompousporcup...
World Chat Champion



Joined: 15 Apr 2015
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PostPosted: 11:12 - 21 Jun 2017    Post subject: Reply with quote

did you ever get this one running again?
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Old Thread Alert!

The last post was made 6 years, 282 days ago. Instead of replying here, would creating a new thread be more useful?
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