Splitting the cases

toastyhamster · Post by **toastyhamster** » Thu Sep 10, 2009 5:34 am

I'd rebuilt the topend before I realised the kickstart wasn't engaging, so I'm attempting to split the cases from the bottom and leaving the top untouched. I've removed all the nuts/bolts, rotor, clutch etc but I can't get the cases apart. Any tips? I can get the right side to move slightly but the front left won't budge at all.

LOUD MOUSE · Post by **LOUD MOUSE** » Thu Sep 10, 2009 7:25 am

Did ya remove the 2 nuts on the top case under the carbs?. .......lm

toastyhamster wrote:I'd rebuilt the topend before I realised the kickstart wasn't engaging, so I'm attempting to split the cases from the bottom and leaving the top untouched. I've removed all the nuts/bolts, rotor, clutch etc but I can't get the cases apart. Any tips? I can get the right side to move slightly but the front left won't budge at all.

toastyhamster · Post by **toastyhamster** » Thu Sep 10, 2009 8:45 am

:-) Yes I did.

Found a bigger mallet and with some persuasion it's come apart, some pretty solid red hermitite on the faces.

Found the problem with the kickstart - the pawl, spring and pin are missing completely. Anybody got a set?

Bit puzzled as to that end of the shaft as well. The manual I have doesn't show a washer but there was one on mine, should there be one there between the shaft and the end locator?

davomoto · Post by **davomoto** » Thu Sep 10, 2009 2:40 pm

Ohio cycles has the three parts you need, spring, pin, and pawl. Sounds like someone spaced the trans with a thrust washer? Very thin washer?

davomoto

toastyhamster · Post by **toastyhamster** » Fri Sep 11, 2009 2:39 am

It's not very thin at all, it's about the width of the copper head washes so pretty meaty. I'll put it back together as per the diagram.

toastyhamster · Post by **toastyhamster** » Thu Sep 17, 2009 12:16 pm

Well I now have a used kickstart pawl in my greasy mitts.... Bill Silver says it shouldn't be worn at all but there is a very very small flat spot on top of it - is this enough to worry about or given I'll be doing very low miles shall I ignore it and just put it in?

I know there's a new one on ebay :-)

toastyhamster · Post by **toastyhamster** » Thu Oct 01, 2009 11:26 am

Oh well - I bought the new one - thx Fred.

I've fitted it but I can't work out how it works. If I turn the shaft it either engages or when rotated the other way quickly it'll clickety-click as the pawl pops in and out of the recesses, if I slow it down it'll stick in place and the transmission rotates. Is this right? I guess the clicking would happen as the kickstart returns into place.

Turns out on closer inspection that the washer I found is handmade and looks like it is there as a shim - but it's about 1mm thick, still seems not to be doing any harm and reading up on shimming I think I'll leave it in place after all.

Hoping to get the engine back together tomorrow.

On a brighter note while I was waiting for the pawl I fitted the rubber mudguard and the rear number plate, so back end is now done.

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Splitting the cases

Splitting the cases

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