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October 27th, 2005, 10:10 AM   #1
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kickstarter revisited

I found out something that has me stumped. After I did all the work to the kickstarter this is what I found out. If the bike is leaned over toward the kickstand it can be kicked over but if the bike is up right the kickstarter has no resistance at all (with the exception of the spring). I know it shouldn`t do that. Could a washer be out of place or something like that? I thought my leg was well enough to try to start the bike. Now it seems like I over looked something. Thanks for any tips or ideas.
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October 27th, 2005, 01:16 PM   #2
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Re: kickstarter revisited

Bill,

Here are 2 pages from my 1999 Work Shop Manual.

Does your starter look like this, did you put all of the parts back in?

Joe
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kickstarter revisited-pages-workshop-manual-1999_page_2.jpg   kickstarter revisited-pages-workshop-manual-1999_page_1.jpg  
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October 27th, 2005, 01:29 PM   #3
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Re: kickstarter revisited

Thanks JoeUSA that is what I went by. I pulled everything out today and I still don`t see why the starter does what it does. All the kickstarter parts are there so it should work but it doesn`t. The shaft has some free play but would need that to get it through the case. It is not engaging in the up right position. I will see what I can come up with tomorrow. Thanks
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October 27th, 2005, 03:32 PM   #4
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Re: kickstarter revisited

for some reason the 'keyhole' shaped pin is not flying out into the wheel and locking in? can't think why though.

regards

taffy
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October 27th, 2005, 06:44 PM   #5
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Re: kickstarter revisited

Originally Posted by Taffy
for some reason the 'keyhole' shaped pin is not flying out into the wheel and locking in? can't think why though.

regards

taffy
Taffy is the engagement sledge once mounted supposed to be tapered to the edge or flat edge wise? Back when I first worked on it the keyhole shaped pin was locking in. The pin locks on the sledge. Could the sledge interfere with it engaging? It wasn`t loose like last time. Tomorrow will tell. Thanks.
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October 27th, 2005, 07:04 PM   #6
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Re: kickstarter revisited

I just recently did mine and when I pulled it out the little spring that rests against that sledge fell out. Don't know if that helps.
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October 27th, 2005, 07:19 PM   #7
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Re: kickstarter revisited

wildbill,

Is it possible that the tiny spring shown in this picture has fallen out or was not placed back into the kickstart shaft upon reassembly? Im thinking on the same line as Taff, sounds like the engagement key is not moving into position as it should, this would be why you are only feeling the resistance of the return spring. Another possibility is that the engagement key is getting "hung up" or "binding" on something as the weight from the components shifts around from upright to tilted??? I would look closely at these and also to see if the teeth on the gears from the gear wheel are locked in tight with that of the intermediate gear wheel. I will being working on these same components on Saturday morning so if you find anything please make sure you let us know your findings.

p.s. the enclosed pic resolution is not very sharp, but I wanted to keep the download as short as possible, should be enough for you to get the idea though.

Regards,
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October 27th, 2005, 07:30 PM   #8
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Re: kickstarter revisited

My engagement sledge had burred over a bit that was causing the key to bind and stick a bit, with the new sledge no problems. it would return to its position after kick and release the key.
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October 27th, 2005, 08:05 PM   #9
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Re: kickstarter revisited

Originally Posted by Wilson
My engagement sledge had burred over a bit that was causing the key to bind and stick a bit, with the new sledge no problems. it would return to its position after kick and release the key.
Wilson,

When you say "burred over a bit" what exactly do you mean by this? Was the key bent or had some of the metal roughed up on the edges causing it to stick on something? Did you find out what was causing the "burring" or was it just wear? Mine still looks in good order but I may want to inspect it more closely if you can describe your findings...

Thanks,
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October 27th, 2005, 08:29 PM   #10
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Re: kickstarter revisited

Wilson,

After reading your post again I realized you were speaking of the crescent shaped metal piece and not the key that had the burrs, correct? I remember also that mine does show some signs of wear and also included a picture of it in my gallery for anyone that may be interested Sledge Wear. Let me know if this is correct so that I don't mislead anyone into looking in the wrong place.



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