Join Date: Mar 2010
Location: Western North Carolina
Motorcycle: GSXR 750K6, 2007 Kawasaki Z1000, Aprilia SXV550, DR650
Re: weird noise when it starts
The starter clutch (overrunning or sprag clutch) is actually bolted to the back of the rotor (the flywheel with the magnets). If you take the cover off, you should be able to move the large gear behind the rotor opposite the engine direction of rotation and it should move smoothly. It will lock up in the other direction.
The two other gears are idler/reduction gears. If you check the parts breakdown, there are a couple of spacers on the gear next to the starter output shaft. I don't know if they are left out if they will cause any interference or stange noises.
It's just me, but if I did this work on the bike and it made strange noises afterwards. I'd take it back apart to recheck my work.