KZ200 starter woes

05c50 · Posted: Sun Aug 17, 2008 6:43 am Post subject: KZ200 starter woes

I recently picked up '79 Kz200 for my wife. It has 2300 miles on it and it's in pretty good shape. I had to do some carb and tuneup work on it, but now it runs great. The problem is the elecric starter. If I was riding it,I'd just use the kick, but my wife wants the electric starter to work. When I first got it, the starter clutch would just squeal and then spin free. I've got some MMO in the oil right now and it seems to be freeing up a little. Does anyone have any experience with these things? If it comes to it, I have a manual and can pull it apart, but I'd rather not do that.

........Paul

KirkN · Posted: Sun Aug 17, 2008 6:55 am Post subject:

What a cool little machine! And, in great shape, too! I owned one of those back in 1991. I picked it up at a garage sale for $25 so that tells you what condition it was in. I completely refurbished it and rode it from West Palm Beach to Daytona Beach for bike week one year, a trip of about 200 miles. I eventually sold it to my older brother, who still owns it! But, yours looks MUCH nicer.

Anyway, how does the starter on these bikes engage? Many of the starters I've worked on over the years use small rollers that engage with the rear of the flywheel / alternator rotor and disengage when the engine begins spinning on its own. Sometimes there will even be little springs in there to help out with the initial engagement. They can get stuck in the retracted positon, or the little springs can fail (they look like the springs in a ball-point pen).

The MMO might work out, but I think I'd be inclined to read the manual about how the system is supposed to work, and then start taking things apart to see what's what.

Good luck with it.

Kirk

05c50 · Posted: Sun Aug 17, 2008 2:57 pm Post subject:

You nailed it, thats exactly how the starterclutch works- 3 spring loaded rollers engage on the rotor. I'm going to leave the MMO in for about 50 miles,if that doesn't work, I'll have to tear into it. But........it's riding season and I hate to start a project right now. When tha the snow flies, I'll do a engine off restoration.I was able to free up a starter on an old 'wing using MMO , so I hope this works. I'll keep you posted.

...........Paul

05c50 · Posted: Wed Aug 27, 2008 7:36 pm Post subject:

Well, I finally got tired of jumping off my bike to start my wifes KZ200 when she stalls it, so I tore into the starter/clutch. The three little rollers are worn flat. I have to replace them and the pins. Best part is that they're still available and pretty cheap. We'll see if this fixes it.

...........Paul