Kickstarter - kicking fresh air

[toastyhamster]

Hi,

I've put the generator case on, and tested the kickstart - nothing happening - it just rotates anti-clockwise not engaging anything ant not turning the engine over, it springs back kinda ok but I have a new spring for that anyway. What could it be? There is around 180 degrees of free movement between the clockwise and the anti-clockwise stop.

The electric starter turns it over ok so I'm not going to split the cases until I've had it running in case there are other problems.

Also - is there a ball bearing in the clutch actuator? There seems to be a recess for one and I think there was one in when I took it out but it's not in the parts manual - seems to work ok with.

And just found something else - I can't get the rev gear cover on as the left hand cam sticks out too far. This one is very odd as the shoulder the bearing sits looks perfectly aligned with the bearing and the head.

[LOUD MOUSE]

The spring installs as you look down on is as an (S) would look.
You must have the ball bearing installed.
The bearing on the "rev" tach. drive side of the head must be apx. 5/32 inch into the bearing hole so the lip/edge on the engine side of the cover centers the cams. .............lm

Hi,

I've put the generator case on, and tested the kickstart - nothing happening - it just rotates anti-clockwise not engaging anything ant not turning the engine over, it springs back kinda ok but I have a new spring for that anyway. What could it be? There is around 180 degrees of free movement between the clockwise and the anti-clockwise stop.

The electric starter turns it over ok so I'm not going to split the cases until I've had it running in case there are other problems.

Also - is there a ball bearing in the clutch actuator? There seems to be a recess for one and I think there was one in when I took it out but it's not in the parts manual - seems to work ok with.

And just found something else - I can't get the rev gear cover on as the left hand cam sticks out too far. This one is very odd as the shoulder the bearing sits looks perfectly aligned with the bearing and the head.

[toastyhamster]

I've fixed the rev counter cover, the bearing wasn't quite seated.

Puzzled over the kickstarter though - I'm assuming something in the crankcase is bust - the kick shaft that goes into the crankcase on the generator side just rotates freely through 180 degrees before coming to the stops on either side.

[LOUD MOUSE]

Remove the cover and turn the KS shaft closk wise untill it won't turn. Push the start lever so the 2 index marks on the inside gears are aligned and install the cover.
Is the spring installed like an "S"?. .....lm

I've fixed the rev counter cover, the bearing wasn't quite seated.

Puzzled over the kickstarter though - I'm assuming something in the crankcase is bust - the kick shaft that goes into the crankcase on the generator side just rotates freely through 180 degrees before coming to the stops on either side.

[toastyhamster]

Lots of little tricks to these bikes isn't there?

I've done that and now presumably the shaft is in the correct position, the lever can now be turned clockwise around 180 degrees but there's no resistance, the spring (installed as an S) then returns the lever to the upright position.

[e3steve]

Without wishing to be the bearer of bad tidings, Toast, it sounds like the pawl isn't engaging with the ridges inside first gear cog. I think the exclamation begins with a large F, followed by a vowel and two consonants.......

I hope I'm wrong, as that means dropping & splitting the motor.

[toastyhamster]

Hmmm, I'm not sure whether to deal with this now or get it running first and see what else I might have to deal with.

Am I right in thinking that the bottom end can be stripped with the motor (removed) inverted so you don't need to dismantle the top end? House move coming up (finally) so probably be a break in the work anyway, on the plus side when we move I gain a double garage so I'll have a lot more room, I'm currently working in a bike sized space with walking room on one side of it.