Starter Clutch

[gosupes]

For those that have not had the pleasure of cracking open a case to replace a starter clutch, you're missing out. Plain a$$ sucks.
Anyway, on to the question. There was some info here (or rumor) about using a clutch from another model, ZZR come to mind but it's been some time. I couldn't find it so I went to order stock ZL900 part numbers. As luck would have it, the have been discontinued so onto a quest to cross reference some numbers. In the 86 and newer ZG's and the ZL1K, they went to a different style and used it until 2003. From what I can tell, they look to be swappable. If someone has been inside both engines or has some insider info, I would be glad to hear it. I have the parts people sitting on my order until I get this straightened out. Here is what I have.

ZL900 parts:

Clutch, 13193-1052 -- contains multiple smaller parts like rollers
Boss, 13061-1112
Gear, 16085-1118


ZL/ZG parts

Clutch, 13193-1057 -- This has 2 parts, 13194-1086 and 92048-1065
Boss, 13061-1191
Gear, 16085-1173
Screw, 120P0612



Now in addition to this, I am replacing the idler gear that goes between the starter motor and the clutch gear due to chipped teeth. The ZL900 has been discontinued.

ZL900, 16085-1119

ZL1K/ZG, 16085-1104

These should be (almost?) the same, all the other supporting numbers like the shaft are the same on both models. They have different starters but the physical gear dimensions on both starters are the same, so the tooth count on the idler should be as well. Can anyone shed light on this? I am going to try and place the order tonight or tomorrow AM and once I get it together, a stick can be created in the tech section. The funny part is, after you total everything up, the newer parts total come out to be about $20 cheaper, so there is some good news.

[zlMark]

Gremlin mentioned the other day just what you said about the difference in years. Can you think of any bikes other then the early ninjas/eliminators that had starter clutch problems?

I would bet that any of the components you are replacing could be replaced with the newer parts. We did use a old starter in a newer motor on Markus56's swap. The only thing I would look out for on that 16085-1119 is that the gear that drives that is the same? I haven't been in to the motor to know any better.

Here's a pic of a newer unknown starter clutch out of a zl motor

[Bacchus]

been there done that....starter clutch... AAaaarrrgh..!

I should have the idler gear from a zl9 somewhare around here.... could you send me a link or a photo and I'll see if I have one..

as far as the "swap-able" starter clutch .... I thought it was a zx starter clutch that was said to be an upgraded unit... not absolutely positive on that though...

[Jarney]

Read through this very long thread - it mentions the zx-11 starter clutch. Later.

http://www.zl-oa.com/forums/showthre...starter+clutch

[Jarney]

Page 5 of above link. Later.

[Jarney]

Here's another one - zzr1100. Later.
http://www.zl-oa.com/forums/showthre...starter+clutch

[gosupes]

Okay, after doing some reading, the clutch, p/n 13194-1086 is the same as the newer ZX11 and ZRX1200 and is what's called in the superseded list on the ZL1K (old ZL1K number is -1067). What's different in all the setups is the gear/race and the boss on the other side so those will have to be replaced on the ZL900. I am going to stick with the numbers from the ZG/ZL1K diagrams. Safer assumption that everything is going to fit.

Mark, that pic appears to be the newer style, but who knows is it's the superseded part. The gear number you mentioned needs to be replaced due to it's the race the clutch bearing rides on. I'm assuming the teth on the outside are the same but we'll see when it comes in.

Bacchus, will post a pic in a couple of minutes here.

Okay so I exaggerated a bit on the part about a "couple of chipped teeth". Nice, huh? It started with the clutch slipping, then aggravated by the binding clutch chain and chipped gear replaced last summer. Then the idler gets chipped from all the jerky motion trying to start the engine. That in turn eats up the starter drive. What a mess. If I could find a replacement motor for a decent price, I would have gone that route.

[Bacchus]

that part looks just like the one I'm holiding in my hand right now......is this the only part you need?

[gosupes]

I wish.

No, I ordered all the starter clutch parts to change from the ZL900 style to the ZG, ZX, ZZR style. Boss, clutch, clutch gear/race, gaskets, idler gear, etc. Hold onto that part. If the people at the parts place come back and say the new gear is no longer available or backordered, I will slip some cash your way for it. Thanks for looking tho.

[Bacchus]

how much did all that stuff set ya back?

double check your starter clutch before you install it. the one I had to replace was brand new... started the bike once and died...was not properly assembled at the factory and was not discovered untill it was removed