KLR600 Starter Clutch - Kawasaki KLR 650 Forum
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post #1 of 2 Old 05-02-2020, 10:57 AM Thread Starter
Join Date: Apr 2020
Posts: 3
KLR600 Starter Clutch

Hello everyone. My mission is to fit an electric start to my KLR600 Supermono race bike. So Iíve fitted a KLR650 rotor and starter gear with sprague clutch. Only to find that the 650 rotor doesnít fire the 600 CDI. So now looked at fitting 650 starter clutch to 600 rotor. Doesnít fit. The 650 has much larger one way clutch and 5 bolt mounting to the rotor. So can I modify a 650 rotor to fire a 600 CDI.

Or has someone out there got a starter clutch gear for a KLR 600. Part number 16085- 1206.

Or itís back to paddock rollers and bump starting.

Stay safe KLRistas.
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post #2 of 2 Old 05-02-2020, 12:14 PM
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Tom Schmitz's Avatar
Join Date: Feb 2009
Location: Redondo Beach
Posts: 8,095
What year bits are you using? This is important to know.

The only KLR600 rotor that I have on hand is an '84, and that is useless to glean information from because it was a one-year-only rotor, not compatible with electric start, and the reluctor bar was clocked completely differently.

Here are the Gen 1 ('87-'07) and Gen 2 ('08+) rotors. The photos show the relative placing of the reluctor bar.
This is the Gen 1:

This is the Gen 2:

If you can look at the rotor that you have, perhaps you can modify it to mimic the reluctor that is on the KLR600 rotor that you had in place. The KLR600 reluctor was long and interrupted. The Gen 2 reluctor is long and continuos. The problem is that I don't know how long the KLR600 was, in terms of crankshaft degrees.

There was a guy in Mexico who modified a rotor by welding a pad on it. I was aghast, as welding usually has bad effects on magnets, but he said it worked and the charging system didn't seem affected.

I know this is not a great deal of help, but where do you think you can go from here?

Tom [email protected]

ďOn the way downtown I stopped at a bar and had a couple of double Scotches. They didn't do me any good. All they did was make me think of Silver-Wig, and I never saw her again.Ē -Philip Marlowe

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