Starting issue got worse

[SiRen8]

Thanks Ruffus, this is really useful info 

[SiRen8]

Hi Ruffus,
I've now split the engine so I can see the starter clutch etc. Could you explain to me how this item works as the large cog which spins the engine is loose and move able? I thought the starter clutch was all one piece?
Many thanks
S

[Ruffus]

Here we go:
- starter clutch IS one piece, but has to be driven by something too (pls see pic when dismantled)
- the other pic shows you (arrow) where the starter sprocked grips in
- further down chain and drive for oilpump
BTW: watch out, this big special 4- pronged nut has LH tread

[SiRen8]

Here we go:
- starter clutch IS one piece, but has to be driven by something too (pls see pic when dismantled)
- the other pic shows you (arrow) where the starter sprocked grips in
- further down chain and drive for oilpump
BTW: watch out, this big special 4- pronged nut has LH tread

icant see any pics?

[SiRen8]

Ok i can now see the pics and all looks the same other than i havent yet removed the castle nut to release the starter clutch. I think the Starter Clutch is broken but wont know until i remove it. Is there a pin or something that locks that castle nut?

[Ruffus]

No, no pin nothing, only this nut has LH tread!!
Means to unlock, turn it CLOCKWISE.

[SiRen8]

Ok ive ordered a special tool to remove the Castle Nut. its a pity i cant post pics as it says they're to big...

[Ruffus]

In case you don't get this tool, it can easily made from a fitting socket using a small flex to cut it out.
For pics: take pics with your smartphone
- minimize them with an downloaded app
- put them in your script

[SiRen8]

In case you don't get this tool, it can easily made from a fitting socket using a small flex to cut it out.
For pics: take pics with your smartphone
- minimize them with an downloaded app
- put them in your script
Castle Nut Tool wasn't long enough

[Ruffus]

This "castle-nut" is easily to be opened(clockwise) with a chisel and hammer, once unlocked thenwith pliers. Don't worry about a few schratches on this nut.

[SiRen8]

Removed the castle nut and then the drive cog, the starter clutch was attached by 3 Allan key screws. One of them was really loose and has been rubbing the back of the cog....

[Ruffus]

Removed the castle nut and then the drive cog, the starter clutch was attached by 3 Allan key screws. One of them was really loose and has been rubbing the back of the cog....

...degrease, check sprockets for mechanical faults and back in again. LOCTITE for hydaulic is used on this allen key nuts.

[SiRen8]

Should I get a new starter clutch etc just incase?

[Ruffus]

Yes, would be good, BUT will highly depend on
a) availabilty
b) price at US ?
Here in Italy I would not hesitate a second.
(pls see pic)

[JJJoseph]

Yes, would be good, BUT will highly depend on
a) availabilty
b) price at US ?

These parts are also shared with smaller Kawasaki ATVs. I use Kawasaki parts routinely.  The Kawasaki parts people are clueless about the interchange codes so you have to do some of your own legwork.  But the parts come in a Kymco package with a Kawasaki label attached. Note the attached photo is just an example, not the part you're seeking.