Starter clutch problems also scratched up engine wall

[Dafske]

Hello bikers,

Im rebuilding my ltd454 but i came to a well known starter clutch problem. i think the starter clutch is broken, so when i removed the fly wheel and the clucth i saw that my engine wall has those start up scratches. See picture

drive.google.com/file/d/1J6_cZqByID9SisdQNDKcJ6CzjX8sLIWM/view?usp=drivesdk

what i found out is that i think the washer between the starter clutch and the guide chain has some damage. Normaly the thickness of the washer is 1mm but i measured mine and it was 0.88mm. Could that be the reason of those engine wall scratches?

Also here is a picture of the starter clutch

drive.google.com/file/d/1JHDSCzDCstSlf2wIqLLFP5fN3IfkSq4P/view?usp=drivesdk

drive.google.com/file/d/1JRPrd1nhOFvaYDcMBXxSqZkB83QQcofg/view?usp=drivesdk

and i saw that the fly-wheel had some marks of the starter clutch rollers. Is this a problem?

drive.google.com/file/d/1JLK5gqjxV7cevtKGBnpkckZuNUuXVZsI/view?usp=drivesdk

All im asking is that im on  the right track with the problem here . Because i found a kit online to replace the clucth but as you know it isn't cheap.
here a link to the kit: www.cmsnl.com/products/product_quickview.php?partcode=131931060

Thanks in advance!

Davey Cornelissen

[bikeman]

I cannot see the pictures seem not to have loaded properly try again using a different method. it would help.

[Dafske]

I've added google drive links hope it will work now

[Dafske]

The chain guide also has some play on the engine crank shaft. Here a video.
drive.google.com/file/d/1KC35D-j3CpQrvnHiAP22LA2jFlQh74kd/view?usp=drivesdk

Also i picture of a scratch mark on the start clutch it self.

drive.google.com/file/d/1K7Z5VMh3b0RQEBoJOeeZSFfVc8k9fiF2/view?usp=drivesdk

[eaglerider]

In the pic of the starter clutch, I see a crack, not a scratch....it needs to be replaced. best to replace everything, especially, if your plans are to keep the bike long term. I know, expensive....look on ebay for a good used, serviceable one from an LTD 454, or Vulcan 500, may be cheaper, and then get a set of new rollers and springs for it.

[Dafske]

Oke thanks but can those scratches on the engine cause any harm?

[eaglerider]

Engine case should be ok

[Dafske]

Eagle thanks for the help. I have one more question the fly-wheel has those brown glue parts on the side of the magnets. I remove some of them because they where already comming lose is that a problem?. Here a picture:

drive.google.com/file/d/1L7mOgImXB_mFwpI9zsV-pbQ6dabdIqtH/view?usp=drivesdk

Thanks anyway

[eaglerider]

Exte adhesive to help hold the magnets. Reading in the forum, you will find that due to age and operation, these magnets can come loose and shatter. This results in likely damaging the stator, getting the oil contaminated, and ability to provide not enough "juice" to charge the battery, or even to keep the engine running. I know it is more expense, but you might consider obtaining an available, later model flywheel in the near future. That flywheel is also mentioned in the forum. It has a one piece magnet, and is a much better design.

[Dafske]

Hey guys i have a question. i have found a replacement flywheel for the ltd 454.
Does it fit out of the box?
or do i need to make some adjustments?
heres a link of the product: 
www.ebay.nl/itm/Flywheel-Magneto-Kawasaki-EN400-EX400-GPZ400-EN500-EX500-GPZ500-RO3-/331348934330
Thanks again.
Cheers!

[bikeman]

YES.  it is designed to fit the 1st gen engine ignition system so will work straight out of the box.

[Dafske]

Hey guys its all working again i ordered all the parts new. But now i need to tighten the altenator bolt to the crankcase. But i have no idea to lock the flywheel from moving  in order to tighten it. I have a torquewrench but thats only righthand working. So How did you guy's tighten the altenator bolt?
I was tinking an air inpact gun but then again how tight does it need to be. the manual says 69nm. But i have no idea to set that nm on an inpact gun.

thanks again!

[Blaine]

Jan 14, 2020 14:17:15 GMT -6 Dafske said:

Hey guys its all working again i ordered all the parts new. But now i need to tighten the altenator bolt to the crankcase. But i have no idea to lock the flywheel from moving  in order to tighten it. I have a torquewrench but thats only righthand working. So How did you guy's tighten the altenator bolt?
I was tinking an air inpact gun but then again how tight does it need to be. the manual says 69nm. But i have no idea to set that nm on an inpact gun.

thanks again!

I just use a strap wrench to hold it from moving.....I just put it good & tight with a drop of blue lok tite.

[yaatri]

Jan 14, 2020 14:17:15 GMT -6 Dafske said:

Hey guys its all working again i ordered all the parts new. But now i need to tighten the altenator bolt to the crankcase. But i have no idea to lock the flywheel from moving  in order to tighten it. I have a torquewrench but thats only righthand working. So How did you guy's tighten the altenator bolt?
I was tinking an air inpact gun but then again how tight does it need to be. the manual says 69nm. But i have no idea to set that nm on an inpact gun.

thanks again!

I use an impact wrench and torque limiting extension bars in such situations.