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Discussion Starter #1
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
Flywheel bolt
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.
 

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Premium Member
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Discussion Starter #2
First drawing shows flywheel, flywheel bolt and bolts for oneway bearing/clutch
Second is picture of two gear shaft (Limiter)
Third shows limiter, and ? to one way bearing/clutch.
 

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Discussion Starter #3
Update:
The flywheel bolt is right hand threads, easily came out.

I determined the male threads on the flywheel for a puller are M35-1.5mm pitch.

I thought I could just get a Metric nut and use my two jaw puller. It turns out M35-1.5mm is an odd size. I finally found a spanner nut with the correct threads. But my puller will not pull the flywheel :banghead:. Either the jaws pop off, or the puller "leans" and comes off. I have to put a lot of pressure before those things happen. I tried tapping the puller bolt with a hammer. I have NOT used heat (flywheel has magnets and rubber parts) or an impact wrench (worried about damage to the crank).

I was able to turn the crank with my puller attached and determined it has to the be the one way bearing that is behind the flywheel that has failed.

When looking for a M35-1.5mm puller, I have found several, but when I put the year, make and model in the "compatibility" chart, they say will not work for that model? :dunno: :nunu:

I either have to take a chance buying a puller, or put it back together and tell my friend he will have to take it to a dealer to fix. :flag_of_truce:
 

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Discussion Starter #4
I could not find a puller that was said to work on this model :nunu:

So of several on Amazon, I bought the one with the best reviews for durability (ones no one broke). That had the correct female threads.

I found the reason it said it would not work on this model. The push screw was not long enough. The end of the crank is recessed in the flywheel. 5/8" longer screw would have been fine. All the manufacture has to do is make pusher screw longer and it would work on this and probably other models :banghead:

I could put the retaining bolt back on, but leave a gap for the flywheel to move off. But one reviewer complained the bolt just turned in as the pusher bolt was tightened. :flag_of_truce:

So I found a round steel spacer that fit inside the flywheel center hole and rested against the crank. The puller now worked :yahoo:
 

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Discussion Starter #5
New gear, one way bearing and engine cover gasket arrived. No where could I find torque specs for the fasteners. I even signed up at a Kawasaki ATV forum and asked :flag_of_truce::banghead:. So I used the chart in a John Deere owners manual. I used Loctite on the one way bearing bolts, none on the flywheel to crank shaft bolt.

I am still waiting for the water pump housing gasket to continue reassembly.
 
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