CL 72 Kickstarter woesCL 72 Kickstarter woesMy CL 72 has been running great, I knew it was too good to last. Apparently I overworked the kickstarter, even though it has been starting on the first or second kick! Last night as I attempted to embark on my evening therapy ride, the kickstarter mech. gave this sickening crunching sound and did not return to its upright and stowed postion- instead it sadly remained pointing at the floor. I removed the lever and the dust cap on the "boss", but I can't figure out how to remove the "boss" or the square of metal the kickstarter mounts to. Is this simply a pry off bit? I do not see any type of bolt that pinches the boss onto the spindle/shaft, and I cannot get the side case cover off without removing the kickstart boss. My schematic does not shed any light onto the removal procedure. Anyone have experience into how this part is removed?
The Kick start comes off with the cover. It slides onto a spline of the kickstart shaft that enters the engine. If it hasnt been lubricated before sliding on or damaged , it can be difficult to remove. Put the arm back on and use the kickstart arm to pull and move left and right and gentle tap with a rubber mallet working in and out might help free the splines.
When removed you should see the coiled spring and there is a circlip underneath if you really need to remove the kickstart boss. If it is limp pointing to the floor perhaps the return spring has failed. You should be able to lift and get purchase on the engine again when pushing down normally if the kickstart paw inside the engine is engaging. You should be able to tell this with the cover on. If not you may need to open the cases of the engine to rectify. Lets hope it isn't that sinister. Good luck
I would ensure that is the issue before ordering one. You probably could get a second hand one from someone on this forum . I believe the CA77 dream are the same but best check to be sure.
As you are in the US you could try http://ohiocycle.com/ ALL250/305 28281-250-000 KICKSTARTER SPRING or http://www.badgercycle.com/catalog_prod ... Spring.htm they seem to be the same for CB, CL and CA
As Waveblaster said...............try to hand-operate the kicker to see if it will engage the motor. If so, the pawl is likely to be OK. Then remove the entire case-cover (after loosening the footpeg bar for clearance) and take a good look at the splines on the knuckle and the shaft. The outer shaft is known to break and ratchet on the splines.
I have a few spares.............but lets see what you may need. Good News/ Bad NewsWith some gentle persuasion with a rubber mallet, and careful application of a small torch, the dog loosened from the spline and I was able to remove the cover with the kickstart assembly intact. I didnt even manage to ignite any of the fuel lines. Spline looks good, and I was able to still engage the motor by cranking the kick lever, (before removal) but the lever is now out of its proper position, it wants to return to a position that is about 90 degrees clockwise of its usual home. See pics.
It seems the dog has somehow rotated within the coil spring mechanism. Of course this is going to make it difficult to kick start from a standing postion. I am not sure what the fix is here, and before I dove headlong into removing the circlip and watching that coil spring fly across my garage, I thought I would post some pictures for your review. Please let me know your thought on getting this mechanism back in spec.
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