A friend brought over his 1994 Kawasaki Bayou 400 4x4. Problem starter motor runs, but engine does not crank.
I pulled the starter. It is simply a motor with the shaft machined as a gear. I works.
I finally figured out how to remove the front drive shaft (prevent access to the magneto cover).
Removing the magneto cover took a long time until I figured out that two bolts were behind the water pump cover.
The starter motor turns a shaft with two gears on it, for speed reduction, Kawasaki calls it a "Limiter" . Starter motor engages at all times the larger of the two gears. Smaller gear engages a gear that drives the flywheel through a one way bearing/clutch. Smaller gear is behind the larger gear, I can't see any of it.
Running the starter with the magneto cover off, I can see the two gear shaft (limiter) turn. Engine does not. I suspect small gear is stripped. I did turn the engine by hand to several different positions in case the flywheel gear is missing teeth. No change.
I can't tear down any further until I get a flywheel puller.
Any one else have this problem, make this repair?
Is the flywheel bolt right or left hand threads?
If it is the small gear on the shaft with two gears that is bad, should I also replace the one way bearing/clutch?
What are torque specs for
One way bearing/clutch bolts
Magneto cover bolts (10, two lengths, but all same diameter)
Water pump cover bolts
I am hoping some one has a Kawasaki tech manual for the torque specs.