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Posted by TOG@Toil on June 30, 2008, 12:27 pm
> > > I have a 1982 KZ-750 E (4 cylinder) that runs great. I am having a
> > > problem with hot starting. When the bike is cold, the starter cranks
> > > the engine over Ok, and the bike starts well. After riding the bike
> > > for a while (10-20 minutes) if I shut the engine off, the starter will
> > > not crank the engine over. It tries to crank, but it just doesn't have
> > > enough power to spin the engine over. The battery is new, and it holds
> > > a charge well, and the charging system checks out Ok. I have 14.5
> > > volts at the battery at 4000 rpm. If I let the engine cool off for a
> > > while, the starter will crank the engine over and the bike will start.
> > > I suspect that my starter is just weak after 26 years of use.
> > > I was just wondering if anybody else has encountered a similar
> > > problem. I am going to try to pick up a used starter at a junkyard, or
> > > possibly pull my starter apart and take a look at the brushes.
> > > Thank You for your help!
>
> > The starter (specifically, the starter clutch) on that engine is well-
> > known for wearing out and/or seizing up over time. It probably needs
> > to be stripped out and the clutch replaced.
>
> > According to the manual, this means splitting the engine cases. In
> > fact, it can be done with the engine in situ, but you still have to
> > remove the sump and engine clutch assembly. It's fiddly, but it can be
> > done.
>
> Doesn't sound like my experience with my KZ650 shagged starter clutch.
> It would slip, and consequently the engine wouldn't turn over, but this
> sounds like nothing is spinning. Even though it's rare for a starter
> motor to go bad, I would suspect that is indeed the problem in this case.
> A clarification from the OP WRT to the symptoms would be welcome.
It's the temperature thing that's puzzling me. Yes, I'd agree that a
knackered starter clutch doesn't usually behave this way, which is why
I was wondering whether, as it gets hot, something's expanding and
sticking in the clutch. I have seen a GT750 (same engine) with a very
sluggish starter before, but then as you say, that could just as
easily have been a defective motor.
>
> As far as replacing the starter clutch, I am quite sure the manual doesn't
> recommend splitting the cases, as you say it can be done by removing
> the sump, BTDT. I have the KZ750 manual (as well as the KZ650 manual)
> at home so I can check if need be.
>
The factory manual probably doesn't. I think it was a Haynes BOL, but
as you say, wtf, as long as it can be done through the sump.
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