starter drive

I've got a 81 csr 650 I'm working on . I put a rebuilt starter in but when i hit the button it turns over a little then the starter drive gear starts to slip and grind like the gear is missing a tooth or two. My question is, do I have to split the cases to change starter gear? Anyone done this before??? ANYONE????
Thanks,Ray aka Boots

boots wrote:

I've got a 81 csr 650 I'm working on . I put a rebuilt starter in but when i hit the button it turns over a little then the starter drive gear starts to slip and grind like the gear is missing a tooth or two. My question is, do I have to split the cases to change starter gear? Anyone done this before??? ANYONE????
Thanks,Ray aka Boots

Sounds more like your starter clutch. This a friction type setup, as opposed to slipping a gear. There are three spring loaded rollers that grab onto a boss that is part of your starter gear set. Usually replacing the rollers and spings does the trick.

On my 1978 kz1000a2, this hides behind the left engine cover and is easy to get at (once the oil is drained). I'm not certain if yours is exactly the same. If you're interested in wrenching your own bike, a shop manual is a good first purchase.

check z1enterprises.com for needed parts (or scour ebay...)

hope this helps...Sam

your starter clutch is bad. it is inside the engine, you do not have to split the cases, but it is an indepth repair. search around a bit there are write ups here. it is a real common problem with the 650/750's

I think you'll have to take off the left side engine cover and remove the stator winding. Then you have to pull the flywheel and the starter clutch is attached to the flywheel.

Thanks guys! It doesn't sound too bad after all!Now to find the time to get back to it.

Boots

Mine grinded like that and wouldn't turn over. Turns out I had forgot to put in a bearing when I replaced the starter gears. D'oh!

flht1997 wrote:

your starter clutch is bad. it is inside the engine, you do not have to split the cases, but it is an indepth repair. search around a bit there are write ups here. it is a real common problem with the 650/750's

he's right. it is an internal part.
not impossible to do without splitting the cases but it is a royal pita.
I found it easier to remove the motor from the bike.
just easier to flip motor around on a bench.
this is what it looks like.





sometimes it's good to have a garage full of crap.
note the rusted bearings.
that poor little 650 was beyond repair. Previous owner left the head off and it sat outside under a tarp for a couple years before I got hold of it. such a shame!
but good for parts and pictures.

I did mine without pulling the motor, just laid the bike over on a stack of moving blankets and pulled the oil pan off. Had so much fun I did it twice.

had nothing to do this afternoon while listening to the Brewers loose to the Giants, so i tore into a spare Gpz motor, and i change my statement. it is a PITA to get to. when you do it besides the starter clutch parts, you will need a clutch cover, and oil pan gaskets and a 1/2 impact is nice and a impact driver for the screws.

You guys are the BEST! I'm lucky to have a spare 750 motor lyin around. I'm gunna try to use that one for the 650. I'll keep ya'll posted!
Wish me luck,Boots