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Almost 20 years ago I road my Vmax 2-up(wife) from Miami to Alaska. Total trip including visits to national parks was 14000 miles. So the Vmax served as a tourer without a problem. I must add that we were much younger at about 50 hrs old.

Wasn't bragging about the mileage, don't ride much anymore. But this was the first time the bike had broken down. I've had other bikes during this time, they're gone and the Vmax is still here. We use to (still do ) call it , "the tool".:biglaugh:

Thanks all for the responses. My starter clutch was no longer cranking the engine. it gave up a few months ago and I finally got around to working on it. I also had one of those nightmare flywheel removals. The clutch had 2 cracks complete from side to side on the same section on the outer and...

Wasn't really worried about determining tooth wear, I was thinking about the starter gear surface that contacts the rollers on the starter clutch and inside bronze bearing wear.

I've seen all these threads on replacing the starter clutch, but when it comes to replacing the starter gear there isn't much information. Even the service manual just says to check for wear, but there are no specs on the amount of wear of the boss or the inside bushing. Does the damage have...

At what point do you replace the starter clutch gear ?

Is there suppose to be any play (in/out) on the gear behind the flywheel? Thanks

On the Kawi, if the float settings are correct, the float valve might be worn, or the float punctured, aLthough you've probably already checked that. On the Vmax, it could be electrical due to bad grounds, plug wires or coil. Do you have an aftermarket jet kit?

Can't bring myself to getting rid of my '97 Vmax either, had it too long, too much fun. MNFatz, I also had an '86 zx1000r. Do you still have yours?