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July 15th, 2013, 09:23 AM   #1
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Kickstarter assembly problems *SOLVED*

Hello

I just bought Fe 650 and previous owner messed with kickstarter so it was jammed. I removed assembly and there was little damage caused by wrong fitting. I tried to re-install assembly, it seemed fine before bolting clutch. Kickstarter gear moved freely both directions until lever was turned clockwise so it only moved same way, not anticlock wise. Until lever was released. So i assembled all back together. After that I carefully tested by hand, and it only turned aprox. 1/4 revolution until it jammed. after released it turned back up and got stuck there?

It works exactly like in this video: http://www.youtube.com/watch?v=KpacGdJwgNA

Only after everything is put togehter it gets jammed..? Does taffmeisters modified sledge help with this?

Is something broken or am I doing something wrong?

Also my freewheel gear assembly is worn so starter is quite useless...
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July 16th, 2013, 02:41 AM   #2
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Re: Kickstarter assembly problems

Sounds like you put it together wrong. I've done it with mine. I think the sledge just gives you more engagement. ( you can kick right from the top ). There is a thread or instructions on here or in the owners docs on how to do it. I would leave the seals off the water pump. Re do it, check it works by re assembling without the seals.
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July 16th, 2013, 12:11 PM   #3
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Re: Kickstarter assembly problems *SOLVED*

Found out that the "finger" on the shaft slips off from top of sledge and jams the whole system. Solved by adding washers under sledge bolts.
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July 16th, 2013, 12:47 PM   #4
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Re: Kickstarter assembly problems *SOLVED*

Have fun with the 650
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July 16th, 2013, 02:03 PM   #5
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Re: Kickstarter assembly problems *SOLVED*

"washers under the sledge bolts"

has this not caused the kickstart sledge to rub on something, if i remember right its all a close fit and none of my 3 husabergs need washers under the sledge bolts .
the kickstart mechanism is a bit fiddly could you of put it in slightly wrong ?
if it works though good luck

cheers kris
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July 16th, 2013, 02:47 PM   #6
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Re: Kickstarter assembly problems *SOLVED*

I've had similar issues addressed by some washers. Can't remember the thickness, but tried a couple of thicknesses until it all cleared and worked OK. Worth doing.
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