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Wolfy December 23rd, 2014 06:35 PM

Kickstart binds after left side cover put on
As the post says, I've been trying to get my 05 650 back on the road.

I went into the clutch side to replace the WP seal. I've been careful to check kickstart shaft, and check for proper movement prior to installing the cover. Plug out of course.

When I install the cover and seat the bolts by hand, the kickstart shaft binds up. Pop the cover back off, and she is as free as a bird.

I've pulled the clutch basket, inspected everything, and put it back together. Cover off, it rolls. Cover on, bound up tight.

What is going on?

Any direction or ideas are greatly appreciated.

bushmechanic December 23rd, 2014 07:17 PM

the shaft probably popped out when the cover was removed and the dog slipped out

if you take the kick starter gear off you will be able to reinstall the shaft properly and see what is going on. use the kick lever to do turn the shaft while installing and to check the dog is operating properly

then to install the gear over the top you hold the shaft in and rotate the gear clockwise as it goes on.

should look like this

Wolfy December 23rd, 2014 08:16 PM

Cheers Bushy!

So, one more time, clutch basket coming back out.

Any tricks to pre loading the spring?

Taffy December 23rd, 2014 11:40 PM

no need wolfy

just lightly undo the sidecover bolts enough to kick the bike OK?

kick as far as you can and hold the kickstart arm down with your foot.

re-tighten the sidecover bolts
now release the kickstart arm.

I also suggest you space out the kickstart sledge plate with two copper washers.



Wolfy December 24th, 2014 11:49 AM

4 Attachment(s)
So looks like Taffy was on the right track!

Looks like I had the ratchet mechanism too far back when I re-installed it. Also explains why I got about 20 degrees of movement on the kicker before binding up.

Other than smoothing out the gouge in the case a little, what do you think of the guide plate, completely knackered? Order new? ($5 for guide $10 to ship)

The shaft and/or gear never got into the actual mating surface of the guide, so I'm thinking that it's still usable. I see how the copper washers would really help to space this out and make up for the axial movement on the shaft. Sort like insurance that I don't do this again.

Say Taffy, how thick do you think I can go on the washers?

Cheers gents!

Wolfy December 24th, 2014 11:58 AM


Originally Posted by bushmechanic (Post 156065)
the shaft probably popped out when the cover was removed and the dog slipped out


I just noticed the screw heads were punched. Great idea!

bushmechanic December 24th, 2014 01:36 PM

Dale lineaweaver put those punch marks in

i put a shim over the shaft between the gear and the case, if you wanted to shim out the guide you could put clay over it and put the gear on to find out how much room there is.

the pawl guide looks OK you could add a spot of weld near the square bit and tidy it up.. they are pretty cheap though

Taffy December 25th, 2014 03:31 AM

1mm or 1.5mm is all you need. anymore and the gear will bind again. you just don't want the pawl falling off again.



Wolfy December 25th, 2014 08:19 AM

I lucked out and live on the other side of town from MotoExotica and Dan.

He had the new guide plate in stock. I tried a 2mm shim first and found interference. Dropped down to 1 mm, and it's like butter, no binding and nice smooth operation.

Thanks again gents!

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