CL77 kickstarter question

husabob · Post by **husabob** » Sun Mar 16, 2014 10:53 am

All, The kickstarter on one of my CL77's skips where the "knuckle" sits on the shaft. Visual inspection reveals that shaft splines are worn, probably the result of lack of grease on the splines. I tried slightly compressing the knuckle, which did result in a tighter fit, however it still skips. It looks like the final fix is gonna be replacing the kickstart shaft, and I have a good spare. I know it involves removing the motor and splitting the cases, which I can do, but would rather not if avoidable. My question: Has anyone come up with a reliable fix that does not involve replacing the shaft? Thanks, Bob B

G-Man · Post by **G-Man** » Sun Mar 16, 2014 3:55 pm

Bob

Check that the knuckle is not cracked. It may be splaying when you use it. If the shaft splines are damaged it may be game over....

G

malcolmgb · Post by **malcolmgb** » Sun Mar 16, 2014 6:10 pm

I recently bought a new kickstart shaft, they are still out there.

kirbb9 · Post by **kirbb9** » Sun Mar 16, 2014 8:18 pm

Check and see if the arm is still loose on the shaft even after tightening. The first one or
two teeth at the bolt area can be ground off and allows the arm to grip the shaft better.
Not my idea, I read it somewhere.

Brady

rustywrench · Post by **rustywrench** » Sun Mar 16, 2014 11:00 pm

I second what g-man wrote. Definitely check the knuckle for a crack. Rusty

husabob · Post by **husabob** » Wed Mar 19, 2014 8:43 pm

kirbb9 wrote:Check and see if the arm is still loose on the shaft even after tightening. The first one or
two teeth at the bolt area can be ground off and allows the arm to grip the shaft better.
Not my idea, I read it somewhere.

Brady

I'm not getting a good mental image of what you are proposing. I did machine off the step at the base of the knuckle in an attempt to get it to grip further down, but that did not help either. I also made sure the knuckle is not cracked. I have a replacement knuckle on the way.

kirbb9 · Post by **kirbb9** » Thu Mar 20, 2014 12:24 am

Husabob, The way that the inside splines fit on the shaft allow the splines to tighten up just where the bolt is pinching. The side opposite may be loose. The splines right by the
two bolts holes (inside of kick starter arm) will be the splines I suggested grinding on.
Hope this helps.