alternator starter clutch assembly - Kawasaki KLR 650 Forum
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post #1 of 15 Old 02-07-2017, 02:37 PM Thread Starter
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alternator starter clutch assembly

The shaft that the rotor and starter cluth rotate on has two washers behind the starter clutch gear. The diagram in the Clymer manual and the dealer parts illustration show both washer to be the same. The dealer schematic shows them with the same part number. However, in my 09 model, one of these two washers is wider and smaller in outside diameter. Can anybody tell me what's up with this?
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post #2 of 15 Old 02-07-2017, 03:07 PM
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Originally Posted by madmotorcyclist View Post
The shaft that the rotor and starter cluth rotate on has two washers behind the starter clutch gear. The diagram in the Clymer manual and the dealer parts illustration show both washer to be the same. The dealer schematic shows them with the same part number. However, in my 09 model, one of these two washers is wider and smaller in outside diameter. Can anybody tell me what's up with this?
The thin hard steel washer probably measures about 32.2-50-1.0 mm correct?
It goes between the starter ring gear and the flywheel Rotor. Part#92022-1650 qty1.

The 2 spacers which Should Be Behind the ring gear measure about 32.2-40-2.0 mm correct?
Part #92026-1474 qty2.

You need all three in the correct places.
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post #3 of 15 Old 02-07-2017, 03:11 PM
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There are three 'washers' in the assembly. There should be two rather thick spacers that have a wall thickness nearly the same as the spacer thickness. These, as you know, should go behind the starter gear/clutch.

Then there is a large washer that is about 1mm thick that should go between the starter gear/clutch and the rotor.

Look to see if that washer is there and if one of the spacers may have been mixed up and put in its place.

I presume you are not the original owner and that someone has been in there before you.
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post #4 of 15 Old 02-07-2017, 07:25 PM Thread Starter
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Thanks guys. Sad to say, I am the original owner. About three years ago I did the doohickey upgrade along with the torsion spring. It must have been at that time that one of those washers got left out, though I have noticed nothing negative over the many mile since. Anyway, I have ordered a new washer ($16). My jug and head are at Mike's for a bore job and reconditioning. I have plenty of time for the order to get here before I need it. Again, thanks.
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post #5 of 15 Old 02-07-2017, 08:04 PM
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Thanks guys. Sad to say, I am the original owner. About three years ago I did the doohickey upgrade along with the torsion spring. It must have been at that time that one of those washers got left out, though I have noticed nothing negative over the many mile since. Anyway, I have ordered a new washer ($16). My jug and head are at Mike's for a bore job and reconditioning. I have plenty of time for the order to get here before I need it. Again, thanks.
If you did the EM Doo-Hickey up-grade three years ago, I would like to ask what prompted you to go back into that area and possibly discover your Old Error?

Lack of full engagement of the one-way starter sprag clutch 'might' cause the starter clutch to 'slip then grip' with some abnormal noise. But with a bike Primarily parked on the Left side, side-stand that 'almost can't happen'.

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post #6 of 15 Old 02-07-2017, 09:24 PM Thread Starter
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Why did I go back into the doohickey area? Since I have shipped the block and head off to Eagle Mike's to have it bored out, I figured there was a series of maintenance things I should do as long as riding was out of the question. One of those was I wanted to check the doohickey and make sure everything was alright. It probably wasn't necessary, but I did it anyway.
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post #7 of 15 Old 02-07-2017, 10:35 PM
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madmotorcyclist, I'm curious what you had between the starter gear/clutch and the rotor.

Tom

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post #8 of 15 Old 02-08-2017, 07:20 AM Thread Starter
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Tom, I believe that is where I had the thinner washer with the greater diameter. The thicker water with the smaller diameter was the starter clutch gear.
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post #9 of 15 Old 02-08-2017, 08:02 AM
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OK, got it. At least we know it will run with only one spacer behind the clutch. Probably not ideal for gear engagement, but it worked.

Tom

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post #10 of 15 Old 02-08-2017, 11:05 AM Thread Starter
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Tom, yes we know it will run, but: Often there was an ugly clanking sound coming from the starter area when I would push the started button. It may very well have been due the lack of that one washer as a previous poster suggested.
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