Loose kickstart. FIXED

This is the shaft to my kick start....



Any ideas?

Perhaps the little clip that holds it in busted.

Is there a trick to getting the kick start on?

Thanks

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Post edited by: hobodan, at: 2007/06/20 22:30

I don't think so. I'm pretty sure you have to split the cases to fix it.
Mark

put a slotted screwdriver in the slot and use it as leverage to slide shaft out farther

I don't remember how that shaft is set up in the engine. If it simply pushed in when you were trying to put the lever on, it should simply pull back out with a little luck. There should be ample splines there to tighten the lever up enough to use the lever as a tool to pull the shaft back out.

I dont know about you guys but if the kickstarter pushed in something came loose and I wouldnt run the engine till you get it fixed. Pull the side cover off it might be an easy fix.

I agree...

mariozappa wrote:

I agree...

It looks like it might just be the #22 & #23 clip and screws that might have broke. From the manual it looks like it clips into #19 right about where #19 is pointing

How did it happen might give a better clue to the extent of damage if any. I'm sure one day the shaft didn't just press in on it's own. What's the story?

Well the story is I was trying to figure out why it kept slipping all the time when I was trying to start it. so I took off the armature and I noticed it was a little jittery. I figured that was normal, so I attempted to put a different armature on and I was tapping it with the old armature trying to fit it, I wasn't hitting it very hard, just tapping. It just sunk right into the engine after the 10th or so hit.

I have a gasket coming in tomorrow for the clutch cover, I need to get into their anyways. So we will see how it works out. I hope it's not to serious.

If you´re lucky it´s just the outer circlip (no. 15 in the diagram above) that fell off/broke - if so you should be able to pull the shaft out and put a new circlip on once you get the clutch cover off. Be sure to find the remains of the old circlip, you don´t want any of that around in the clutch housing.

While pulling on the kickstarter shaft, rotate it a bit ccw, you can´t pull it out unless the kickshaft gear (no. 17) is in mesh with it´s correponding gear.

No. 19 in the diagram is the kickstart shaft, no. 18 is the kickstart shaft bushing (or sleeve if you will), the bushing is held in place by no. 22 - the two screws (no. 23) that hold no. 22 are factory staked, they´re not likely to come off. Even if they did the bushing is a tight fit in the lower case, I doubt you could press it into the case just by tapping it.

If you need to access the internals of the kickstart mechanism though, Mark is right, you need to split the cases - you can´t get to the kickstart internals with the output shaft in place.

Po

Post edited by: OnkelB, at: 2007/06/19 15:01

THANK GOD a simple fix!

Turns out the circlip just came loose. I took it off, bent it back, and put it back on! kick start works like a charm now!

This is what it looked like when i pulled the cover:


This is where it needs to be, as you can see, the clip just needed to be reset.


Here it is back together. That spring is EVIL! :pinch:


Thanks for all the help everyone!!!

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Glad you got it back together. A new circlip would be in order. Once they bend they've lost their strength and it'll probably work back out of place again.

The spring is easy to put in place with the clutch basket removed! Most times we make do with the fewest parts disassembled.