Motorcycle Repair: Kawasaki Voyager Starter Chain, kawasaki voyager, starter clutch

Question
Hello Mark
I was wondering if there is an adjustment that can be made to take up the slack in the starter chain on a 1994 Kawasaki Voyager. I am ordering the repair manual for the bike and worse case senario, I am prepared to pull the engine, separate the halves and replace the chain. The bike runs great with no other problems. I have parked the bike until I make the repairs to the starter chain. Starting the bike had got to the point of having to place the bike in gear, rock it back and forth, so the starter would engage the chain,  otherwise the starter would just spin without engaging or turning the chain. The bike only has 25k miles on it. If I have to go into the motor is there anything else I should change as preventative maintenance? I was going to take the bike to the shop to have it repaired but out of the 6 shops that I called, no one had any knowledge of the mechanics of the voyager, and the shops could not give me a ball park estimate on replacing the starter chain. they had no idea. So since I am mechanically inclined(rebuilt numererous car engines and auto transmissions) I figure I will be better off doing the work myself. Any insight and expert advise from you would be greatly appreciated.

Gifford Cordova

Answer
Hi Gifford,

There's no adjustment for the secondary shaft chain.

The starter motor is a Lucas brand and uses a idler gear and clutch assembly. The altenator shares the secondary shaft with the starter clutch assy. The secondary shaft is connected to the crankshaft via small, primary like chain.

I suspect the clutch assy is worn and causing your problems.

Visit "www.buykawasaki.com", click green text "Vehicle Information" and then click "View Parts Diagrams". Select your MC from the menus and see microfiche parts on line.

I don't think starter clutch replacement requires complete teardown. Check the service manual.

Respectfully,
Mark Shively