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post #1 of 11 Old 08-15-2018, 04:21 PM Thread Starter
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starter problem

"84 KL600 electric start
Stored for a couple years, it started well then, if I remember correct, now will not keep starter clutch engaged. When first engaged, a loud clacking sound, engine kickback and if the starter button is kept in, the starter motor whirs and continues clacking.
I have changed the flywheel, clutch ring gear, starter relay and starter button.
Not sure where to go next, any suggestions appreciated.
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post #2 of 11 Old 08-15-2018, 05:13 PM
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How new is your battery and what is the battery's voltage when cranking?
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post #3 of 11 Old 08-16-2018, 08:58 AM Thread Starter
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14,9 volts when cranking.
I also failed to mention that when the motor does start, it runs well. It takes repeated attempts to get the starter to engage and turn the motor over.
No obvious damage to starter gear or any of the related gears.
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post #4 of 11 Old 08-16-2018, 10:05 AM
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A 12V battery cannot put out 14.9 volts when under a 30 amp load, so we are miscommunicating somehow.

I have some points of confusion around your general description. Let me start by saying that my first reaction is "Your battery is weak", which is why I asked how old it was and what the voltage of the battery was when cranking. Without knowing the age of the battery and its cranking voltage that is still my first reaction.

The starter motor turns a pair of reduction gears, which in turn rotate the ring gear which, through the sprag clutch, turns the rotor and the crank.

You have replaced the sprag clutch (attached to ring gear) and the rotor (flywheel), so let's assume the sprag clutch and the bore it runs in are good.

The reduction gears have a built-in torque limiter such that they will slip if the engine somehow kicks back. Perhaps, if your battery is in good shape, the torque limiter in the reduction gears is slipping.

This clacking sound, though, that sounds like a description of a chattering relay. That is an indication of a bad battery. I keep coming back to the battery issue and don't like to see parts being swapped out unnecessarily.

Along the lines of an electrical issue, have you verified that all of the connections to the battery, solenoid, and starter motor are clean and tight?

Tom [email protected]

“Some days I feel like playing it smooth. Some days I feel like playing it like a waffle iron.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
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Last edited by Tom Schmitz; 08-16-2018 at 10:07 AM.
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post #5 of 11 Old 08-16-2018, 10:15 AM Thread Starter
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Tom thanks for the assist.
Checking further, I have verified that the torque limiter gears are not slipping, however the starter (Sprague) clutch is allowing the ring gear to freewheel sporadically.
I did exchange the clutch with a parts bike I have that did work properly when parked, years ago. It does the same thing, (freewheeling).
I have verified also that the washers and spacers are in the proper location on the crank assembly.

At this point I guess I need a new clutch (Sprague) but looking at other threads on this topic, the units for the 600 are discontinued. I'm wondering if the 650 will work, they are available.
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post #6 of 11 Old 08-16-2018, 10:47 AM
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Quote:
Originally Posted by Tom Schmitz View Post
Let me start by saying that my first reaction is "Your battery is weak", which is why I asked how old it was and what the voltage of the battery was when cranking. Without knowing the age of the battery and its cranking voltage that is still my first reaction.
Me too......If I had a dollar for everytime someone had a problem with a "good battery" that turned out to be the battery.....well, I'd have lots more dollars! LOL

Swap it for a known good battery or jump it from a car battery to eliminate this as the issue.


Dave
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post #7 of 11 Old 08-16-2018, 12:38 PM
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Quote:
Originally Posted by jimwade View Post

At this point I guess I need a new clutch (Sprague) but looking at other threads on this topic, the units for the 600 are discontinued. I'm wondering if the 650 will work, they are available.
The only help I can offer there would be to measure the bore in the backside of a 650 rotor and count the teeth and measure the diameter of a 650 ring gear.

Let me know if that would help.

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“Some days I feel like playing it smooth. Some days I feel like playing it like a waffle iron.” -Philip Marlowe

“'Why' and 'How' are words so important they cannot be too often used.” -Napoleon Bonaparte

Sting like a butterfly.
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post #8 of 11 Old 08-16-2018, 01:49 PM
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jimwade,
1985 KL600-B1. 1984 KL600-A1 was kickstart only. I see that the sprag clutch which you did Not replace #13194-1056 is superceded to 13193-0006. This from the rockymountainatvmc.com parts look up. $109.31 MSRP and their price is $84.17, free shipping in the USA.

The new part number is currently being used in the Ninja, Versys, Vulcan 650 twin cylinder engines, according to kawasakipartshouse.com,
https://www.kawasakipartshouse.com/o...earch/kawasaki
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post #9 of 11 Old 08-16-2018, 03:07 PM Thread Starter
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Thanks, just ordered one.
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post #10 of 11 Old 09-10-2018, 02:47 PM Thread Starter
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Put the new starter clutch in from Rocky Mtn ATV/MC, works like a charm.
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