Stator Removal NEW PICS 10-03-11

[thenewguy]

1983 Klt 250 and I am trying to get to my starter clutch. I though my gear puller would work but there is no where to thread the bolts or enough room to pass them through and put a nut on the back side. So how do I pop it off? and is there any precautions to taking all this stuff off. Like I say im trying to ultimately get the starter clutch off and replace it. Thanks

[thenewguy]

I guess I mean the rotor which is what bike bandits diagrams says it is

[cr480r]

using the wrong puller is the biggest cause of damaged components on small engines. Buy the correct tool.

[thenewguy]

I Pulled it off and this is what I found.

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0065.jpg

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0064.jpg

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0063.jpg

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0062.jpg

When I pulled it off the little wheel fell right out and the springs don't seem to have much tension. But I'm not sure if those things falling out it a normal thing or if they should be tighter?

[thenewguy]

Any advice?

[atc007]

Well, I can honestly say,,I have never been in the flywheel of one of these! But that looks really torn up to me? Kawi guys can weigh in,,but I think you're looking at a flywheel, haven't the little barrels torn that up?? You need a new cameraman : ) lol

[1984 honda 200s]

The insides of a kawasaki... Ive never seen a setup like that where a starter has a sprocket and chain going to the flywheel on the crank, hmmm, looks like your flywheel is a little.. worn out perhaps ?

[leevarnado]

that is setup like the new china bikes.kinda looks like that flywheel has a oneway bearing

[thenewguy]

if you look at the first pic theres a woodruff key in there. I missed it cause it is so worn down or possibly the wrong one. shouldn't the key stick up more then that? Yeh the worn down fly wheel is from me trying to start it and the one way engaged for a few spins then would just spin. Possibly jumping over the woodruff key?

[just ben]

the part that normally wears so that the one way bearing wont catch is the hub on that big gear. even very slight wear will make it not grab but the flywheel looks a bit ragged.Its hard to tell with the blurry pics.If the flywheel jump the woodrift key there should be evidence of it in the flywheel hub

[thenewguy]

Where might I Get a new woodruff key from?

[just ben]

Where might I Get a new woodruff key from? small engine shop. the hardware store by me has an assortment. try an ace hardware if you have one around they carry alot that others don't

[thenewguy]

I got an 80 piece woodruff key set. The key that fits best almost seems to tall cause I can't get the clutch to slide right over. Should the clutch just slide on easily or do you usually have to Tap it on?

[just ben]

clutch is on the other side of the engine. if you mean the flywheel it should slide over the key, if it doesnt grind it down until it does

[thenewguy]

Yeah that's what I mean lol.

[thenewguy]

So I got a new cameraman lol and took some better pictures.

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0069.jpg

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0070.jpg

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0071.jpg

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0076.jpg

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0078.jpg

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0079.jpg

The first six show the wear and groves around the edge of the starter clutch.

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0080.jpg

This image shows the actual key way and a grove right next to it. That grove I actually caused when I put my ground down key in.

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0081.jpg

This image shows where the key I took out seems to have actually been sitting for quite some time to have made such a definite grove like that.

So I guess I'm thinking that its probably a safe bet to get a new starter clutch and I was able to locate the actual kawi part number for a new factory woodruff key.

[thenewguy]

http://i481.photobucket.com/albums/rr176/mm1429/IMAG0081.jpg