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February 21st, 2009, 02:28 PM   #1
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What did I do wrong?

OK, so last fall my water pump shaft oil seal failed so I got a new one and replaced it. I am just now getting around to putting the side cover on the bike. I get it all back together and go to put the kick starter back on and it doesn't line up properly. It is either too far forward and hits the clutch cover or too far back and hits the gas tank. When it is the position that hits the tank it won't move even if the decompression lever is pulled in. Of course the battery is dead so I'm charging it now. What could I have done wrong????? The bike was running fine when I took the side cover off last fall.

***EDIT*** I got the kick starter to line up correctly but I still can't kick it!

Thanks,

Mike
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February 21st, 2009, 02:51 PM   #2
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You do not have the kickstart shaft installed properly. You will have to pull the clutch cover and reseat the shaft. I always try the kickstarter once the cover is snugged down to make sure it's right. Your lucky you didnt warp the cover when you torqued it down.
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February 21st, 2009, 02:54 PM   #3
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Not sure I follow Berger. I didn't take the shaft out. How does it come out?

Thanks,

Mike
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February 21st, 2009, 03:00 PM   #4
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it is just on the edge of popping off the crescent that guides the ratchet assy. whenever you pull that side cover, keep your thumb on the kicker shaft to keep it in place. there is a procedure for replacing it in the doc.
and i always follow berger, he's the only one that knows where the trail goes
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February 21st, 2009, 03:01 PM   #5
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Thanks guys, I will check it.
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February 21st, 2009, 03:20 PM   #6
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So do I have to rotate the shaft or something?
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February 21st, 2009, 04:59 PM   #7
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You are goint to have to fiddel with it. Warning....it is a major pain in the ass untill you have done it a few times. As Ned said, there is a procedure in "the owners doc"
http://www.husaberg.org/wiki/index.php/Main_Page

When you pull the clutch cover off you will want to put pressure on the kickstart shaft with your thumb. If not the shaft will pop out, hense your problem. You will not see the problem unless you are looking very carefully. The difference is only like 8-10mm.
When you have it in correctly the cover will fit on flush without much effort.
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February 21st, 2009, 08:36 PM   #8
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Try reading this thread. I went to some trouble to explain the process when I had to replace my kickstart shaft. Pictures and descriptions in my gallery.
http://www.husaberg.org/index.php?name= ... highlight=

http://www.husaberg.org/index.php?full= ... _photo.php

Like Ned & Berger said. It's the ratchet pawl that slips off the crescent that stops the shaft going all the way back in and this often happens inadvertantly when you pull the cover off in the first place.
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February 22nd, 2009, 07:42 AM   #9
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Thanks for all the responses guys!

I got the side cover back off and have fiddled with the kick start shaft but I haven't got it yet.

This might be a dumb question... Do I have to take the clutch off to get it to seat properly or can I leave it on?

Thanks again for the help!

Mike
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February 22nd, 2009, 08:33 AM   #10
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Not sure about that Mike. I had the clutch off anyway. If you do take the clutch off watch out for the timing marks, as the crank and cam gears are timed througn the clutch basket.
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