I had a KLF 300 in yesterday, the owner had removed the starter as it was smoking. Turned out the lead must have been put on badly as the terminal was missing and the post had melted the insulation round it. New fiber washers and a bit of cleaning up and we were good to go. The starter was Chinese and almost new, would it go back into the engine? No it would not. The first Kawasaki I did, I was a bit worried that the spline wouldn't enter the sprocket, but it popped right in, as have all the Kawasaki starters I have done since. This one would't, I got the boss to try, in case I was doing something wrong, but no joy. In the end he suggested laying the bike on it's side and moving the sprocket to the middle of the hole. We did this and the starter went in OK. Anyone else had trouble getting starters back in? Or are the Chinese ones are a bit shorter on the splines so don't go in before the body hits the hole?

 

You should put this in the Chinese section as well. The 300 is made by Kymco for Kawasaki has the same 270cc motor as the Kymco Mongoose 300 I think.

 

I'm not referring to the 2015 Kawasaki, this is the KLF 300 that Kawasaki made from the dawn of Quads until 2007. Some of you must have fitted new starters to them.

 

how did you wire it up to include the rectifier? I washed my bayou and killed it. Now it will pull start but mot crank. this sounds like a simple solution for me to try

 

What rectifier? All I did was clean up the starter post and fit a new crimp on terminal to the starter wire, which was dangling from the front down tube. I know Kawasakis have a rather complex starter circuit with two relays, one a normal starter solenoid and another that I have never touched. I think it is for the neutral lock-out.