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Old November 3rd, 2019, 01:05 PM   #1
juanphatsun
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Name: Juan
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Motorcycle(s): Ninja 250 2007

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Starter clutch removal

I made some inquiries about a starting issues, and after some detective work it's clear that my starter clutch needs to be replaced.

I'm just curious if anyone has any tips and tricks for getting around the specialty tools needed to remove the alternator rotor.
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Old November 4th, 2019, 08:37 AM   #2
greg737
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You might be wondering why nobody replied to this question.

It's because pulling off items that are mounted onto the end of a motorcycle's crankshaft isn't easy, and there's a good chance of damage if you attempt to do it with improper tools, which is why there are specialized tools for the job.

Trying to do this work on-the-cheap often ends up in failure: 1. unable to remove the item, 2. damaging the item you're trying to remove, 3. breaking the on-the-cheap tool you're trying to use (in place of a real/proper "puller" that was made specifically for the job), 4. causing damage to other items (such as the Alternator Rotor)

On the EX250 the Starter Motor Clutch is mounted on the backside of the Alternator Rotor. The Alternator Rotor contains magnets. The magnets inside a motorcycle Alternator Rotor are relatively delicate and can be damaged/ruined if you drop the rotor on a hard surface or if you beat on the rotor while trying to remove it from the crankshaft.

There are specific warnings about this printed in the Kawasaki EX250 Motorcycle Service Manual.
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