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CA-77 kickstart issue after rebuild

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Nick
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Posts: 184
Joined: Thu Oct 15, 2009 2:03 am
Location: Paradise

CA-77 kickstart issue after rebuild

Post by Nick » Sun Sep 28, 2025 8:08 pm

Got the CA engine all back together and in frame. Try to turn engine over with kickstarter and kickstart is locked, moves an inch or two then stops solid. Figure I gotta strip the engine again, so I pull off left cover, clutch, etc. Everything rotates freely, shifts fine. Kickstarter then works fine! Put everything back together, kickstarter is working normal, check timing, kick it over a bit more, just before putting oil/gas in I go to kick it over again and the kickstarter moves an inch or two and stops solid. Repeat the above, use wrench on crack, turns freely, clutch looks fine, shifts normal, then kickstart functions normally again, and is functioning normally now.... When installing the trans shafts, all the bearings fell out of the kickstart ratchet, so I packed them all back in again and all looked good and seemed to function normally....

Clue: I put the transmission from my spare CL engine in the CA ('cause back-cut gears on CL, and too-short gearing on CA). Everything fitted fine, shifted fine, etc. Could this kickstart issue be caused by a random gear-teeth mismatch with the CL gear cluster? Or....?

Thanks in advance.
Do what you've always done and you'll get what you've always had.

Nick
honda305.com Member
Posts: 184
Joined: Thu Oct 15, 2009 2:03 am
Location: Paradise

Re: CA-77 kickstart issue after rebuild

Post by Nick » Mon Sep 29, 2025 9:30 pm

Mystery solved. Was mixing and matching CL parts from a spare engine 'cause the CL clutch plates have twice the friction surface area as the CA plates. Used the CL inner hub also, and that's what caused the problem. It looks the same, but isn't.
Do what you've always done and you'll get what you've always had.

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