Starter clutch sprocket— Opinions

  • TombstoneTom
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Starter clutch sprocket— Opinions

03 Mar 2025 14:30
#909632
I had to replace my original one due the brass bushing got loose and wore the brass bushing lopsided.  I got this one, pictured, as the best one from what was available.  It looks worse in person.  Picture shows after I dressed it up some with 400 and 1000 grit.  This is the side that rides in the crankshaft seal.  Think it’ll leak? Ugh… Thanks! 
1977 KZ400 A1 Deluxe

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  • DoctoRot
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Re: Starter clutch sprocket— Opinions

04 Mar 2025 13:56
#909667
you can try it and see if it leaks. If there are no good alternative used ones you could get it welded up and machined back.
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  • Wookie58
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Re: Starter clutch sprocket— Opinions

04 Mar 2025 15:23
#909671
As a "last resort" you could fill the worst of the marks with "liquid metal" and carefully sand back. To be honest looking at the pictures in your other post I would be more concerned as to "why" this happened. The crank looks to be badly marked where the bush runs and there is an "oil passage" that should supply the bush with lubricant but it all looks dry. If the oilway is blocked the new gear will go the same way and if it seizes will destroy the starter as previously mentioned
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Re: Starter clutch sprocket— Opinions

04 Mar 2025 21:53
#909682
The picture is from a used one I got a hold of. The original one was leaking oil from the seal in the sprocket.  The lack of tension (installed upside down from previous owner. Much like the fork seals) from the “finger” plate that lives in the engine cover.  There was never a starter/clutch problem other than what I figured out the problem of the clutch sprocket moving in and out bashing everything in the other post. My original had zero rust anywhere in there. Oil was freely moving where it should.  The crankshaft marks are from repeated lateral movement.  And it looks dry because I cleaned everything off so I could see all marks and I work clean. Good thing is it looks/feels good after some light polishing with 1k grit. I’ve unfortunately had to run worse looking in large equipment before but I don’t have a multi billion dollar company to back me to afford to run this until new parts (that rarely exist) show up. So I’m being very overly cautious. I think I’ll keep searching for another clutch sprocket.  
1977 KZ400 A1 Deluxe
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