TOPIC:

Won't argue with ya Swest I thought about shimming the new springs but then again mine and most lasted 20 to 36 years so I figure why try to out think the engineer's at Kawasaki.

I really abused mine too....... never kick started it and more than a few compression checks and oiling up and spinning the pistons over every winter. Had problems with it starting for the first time in the spring with the smooth bores too and ran the battery down more than a few years and had to push it. Was always fine after the first start up not sure if I flooded it or vapor locked it or what but no problems for at least 10 or more years now.

Good to see you going with the new sprocket have read about more than a few having to do it over because of not replacing it the first time.

Ya I'm not bashing anyone either trust me there's more I don't know then I do know, And I don't mind being wrong it helps me to learn and not being close minded.
Looking forward to learning more on here about my bike and enjoy all the feedback.
Dan-kz

I was thinking with a smaller motor they decided to use thinner gauge wire for the springs.
Steve

I don't have the option of kick and electric start on the 1981 kz 750 but would like to have both if I could.
The last bike I tried to kick start was a 1972 Honda parallel twin 450cc and I wished it had electric start. Anyway I never got it started
it was built into a cafe racer not a bad bike.But the rear foot peg was not the best place for a kicker.

These springs are very thin, hard to believe they can do the job I know my bike is thirty some years old with 25,000 miles bike was brought up from the USA so its had many starts on what i believe to be original parts.

It would be interesting to compare the gauge of the springs. Do you have a Mic. or caliper. I have a spare set in the shed.
Steve

here is a picture of the spring and roller I do not have a caliper but when I get a chance I will measure the spring
The picture is to show the flat spots on the roller and if you look to the right side you can see a small portion that has not worn and sits taller then the worn part with flat spots . Ed posted pictures of the gear showing the same wear on the 58T gear.I looked at mine and it was smooth. But no way of knowing how much has been worn down.

Seems to me buried in the engine, it will run hotter and get more wear. That's where the primary chain is too?
Steve

Of the three rollers only the one in the picture had this bad wear. I'm thinking this was the death growl I heard when the bike was running and not the cam chain

swest wrote: Seems to me buried in the engine, it will run hotter and get more wear. That's where the primary chain is too?
Steve

The hub that the St. clutch bolts too runs the primary and the sprocket the cam chain so it gets a ton of heat and spinning action.

The pics don't do the spring justice either on how wimpy it is....... it measures 1.500 long (new) old one was shorter by .060 or so.... forget exactly and the coils are .008 ...... a ball point pin I took apart measures .012 and is stiffer. ....... still I guess I'll trust Kawasaki but it makes you wonder.

I had one spring defently weaker also and the other two were too but not quite as bad. All three of my rollers and sprocket had a lot of chatter marks on them.

The new starter clutch also has a metal plate on both sides where the rollers now ride to as where the old one the cast iron (I think it is) rode against one side and there is now I think 4 oil holes on each side where there was only one before. One of the guys we helped a few months ago took a picture of it showing what I mean just not sure which one right now.

Sorry about the picture Quality taken with my phone so i don't have to large of a file upload for the site. But now have a better idea with the measurements. Now I can't wait to get the new starter clutch to see the newer design and four oil holes ya more is better.
So is it a good guess that all the noise I heard was the starter clutch and not the cam chain?
I see allot of people go with a manual chain tentioner and I don't really know if the auto is bad for sure at this point.

Either search "starter won't grab' or go to my page and check this out on my 5th page of threads...... the picture is shown on the last post of that thread..... not a big deal but them adding the metal plate and adding the 3 extra holes shows that they did re think it and re designed it a little. O and I didn't mean your pic wasn't that good I ment it didn't show just how wimpy the spring is in person.

Yes the new clutch came assembled with new original rollers, pins and springs.