Motorcycle Repair: 2004 kawasaki 1500 classic, stator coils, kawasaki 1500


Question
The starter motor spins and does not engage the engine. If I rock the bike, it might engage briefly but then start spinning again. I removed the starter and it tested OK. In the few days before it stopped altogether, there were several times when it would spin but then it would engage and the engine would start. then, one day, nothing. What gives?

Answer
Hi Stephen,

The problem is likely your starter drive clutch slipping.
This is a one-way device that allows the starter
to hold in one direction to turn the engine and
then it slips in the other direction when the engine fires.

The springs and rollers and other surfaces
can get worn down slowly and occasionally
they hold and then slip again.

The parts have to be removed and inspected
carefully for wear. Any wear may result
in it slipping so it is better to
replace as much of it as you can afford.

I would suggest getting a service manual
unless you take it to a Kawasaki dealer
to be repaired.

It is located on the back side of the alternator
rotor under the left side cover which holds
the stator coils on.

You would need a puller to remove the rotor
and some other tools as well to get to it.

It is a common problem on many bikes
and has to be replaced to fix the starting problems.

Good luck!
Wayne S.
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