kick starter Mech.????

down4thakrown · Post by **down4thakrown** » January 12th, 2014, 9:49 am

So I had to put a new main shaft bearing in my 500 and I got it all back toether up to all I had to do was put the exhaust on and add coolant. So I thought I would try turning the motor over by hand and the kicker got half way through the cycle and jammed. So took it back apart and redid it and it would do a full cycle but not return on its own or jam when I try to manual return it. Should I wined the spring before putting the cover on?

other · Post by **other** » January 14th, 2014, 5:16 am

There are dot punch marks on the ratchet gear and kickstart shaft. these need to be aligned. You replaced a gearbox main shaft, but struggle with the simple kicker mechanism ? . . . . have you checked that your gearbox works ? !

down4thakrown · Post by **down4thakrown** » January 14th, 2014, 7:24 am

Ya gear box goes through the gears. I'm thinking I didn't wined the spring clockwise and went counter clock wise. And I lined up the lunch marks. I'll get a pic of the punch marks

Kuma · Post by **Kuma** » January 14th, 2014, 12:28 pm

If memory serves me correctly, the spring only gets a preload that holds it in the up position, when you kick it through, that is when it gets wound tight in order to bring it back to the park position. if you put an extra wind on it then it is probably going into a bind.

other · Post by **other** » January 14th, 2014, 4:52 pm

Kuma is absolutely right. Just align the punch marks, pop the assembled mechanism into place so that the engagement pawl sits under the plate, and then hook the spring in. This involves about a 1/8 turn or less, clockwise as you look at it.

down4thakrown · Post by **down4thakrown** » January 14th, 2014, 6:15 pm

Yea I'm thinking thats where I biffed it. I would just hook the spring with out making sure the pawl was under the plate. Im prerty sure the little tension of the spring helps hold it in place too. Cuz iy would push out jus far enough to grab the clutch basket teeth.That's what I get for trying to rush though.

iggys-amsoil · Post by **iggys-amsoil** » January 15th, 2014, 9:54 pm

And for those who have a Gen III frame, maybe other too, offset the punch makes by one spline and the kicker won't touch the frame or the pipe.

You'll have to figure out which way to go on that.

down4thakrown · Post by **down4thakrown** » January 15th, 2014, 9:57 pm

Good point I'll look into that. My kicker was barely rubbin the frame

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kick starter Mech.????

kick starter Mech.????