550 Kickstarter issues during reassembly

o6550 · Dec 4, 2023

I'm changing the timing chain. When I put the side cover on, everything goes dandy. After I torqued all the cover bolts to spec, I found that the kickstart lever was jammed and wouldn't budge.
I removed the water pump impeller, side cover, clutch assembly, kick starter shaft assembly, torsion spring, and spring-loaded pawl.

I re-insert the kick starter shaft assembly making sure the torsion spring goes in properly while it's also pinned to the shaft plate. It takes some patience, but I'm getting good at it.

Once the kick-start assembly is in place, I reinstall the clutch while making sure the cam and crank are timed before the clutch gear engages both gears. I install the side cover again and get it seated carefully with a soft dead-blow hammer. Just to check, I slide the kick lever on the shaft and give it a try, and it seems to work (maybe a bit stiff, but hard to judge).

Once I torque all the cover bolts down, the kick-start lever is jammed - again. I've done this three times now and it's very frustrating.

I have noticed that it takes very little to have the shaft pop out of position after I get the kick-start shaft assembly in. Even a few bumps (like when I re-install the clutch) seem to make it pop out. It's such a tiny amount, I don't even notice it until I have it all back together and only after I torque down the cover bolts.

Any pointers would be much appreciated.

Taffy · Dec 5, 2023

you need to put a washer on each of the two sledge plate holes THEN fit the sledge plate. 1mm thick is OK. 1.5mm might cause friction. 1mm is often enough.
Taffy

jojo09 · Dec 5, 2023

How's your sledge plate?
If that's worn it slides out easily

o6550 · Dec 5, 2023

Thanks for the responses. So, Taffy, I need to space the plate out 1mm? Maybe if I remove it and give the whole mash-up a good look-over, I'll understand how that will help. Sitting here at my keyboard at 5:30 AM, sipping coffee, it makes little sense.

I will post a few pictures of how it all looks and the condition of the plate.

Taffy, I have your YouTube Kick-starter install video on my phone and will refer to it as I try the install again. I also see that you have a "modified" sledge plate for $10.00 on your website. I wonder how long it would take to get here if you slipped it into an envelope and chucked it in the mail? Besides, I still owe you eight bucks, and I'd be happy to spend 25 to get this issue resolved.

Taffy · Dec 5, 2023

how much do you think the key in the photo is still just onto the plate by? let's not forget that the shaft twists slightly as you kick it, turn it or move it.

Not sure how long after this week. this week is the turning point and Christmas cards and presents will throw 'the usual' figures into touch. usually 7-10 days.

Taffy

o6550 · Dec 5, 2023

Wow, that was fast, and it's very clear what the issue is from your photo. I think I'll need a new plate, as mine has a few nicks in it. I'll try your 1mm trick so I can get this back together. Meanwhile, I will order a new plate. Is your plate 1mm thicker?

How can I add eight bucks to my order? I'll order two plates and you only send one.

Taffy · Dec 5, 2023

The plate is the same thickness, you play with OEM stuff at your peril!

$8 I will get as the post is always a little OTT.

Taffy

o6550 · Dec 5, 2023

I'm on your site now. Didn't I see a sleeve you sell that guides the water pump seal over the shaft? I looked, but can't find it.

Taffy · Dec 5, 2023

here you go.

mounting sleeve is at 101803

Taffy

o6550 · Dec 5, 2023

I removed the clutch and kick-start assembly and inspected the swedge plate (see photos). Then, I reinstalled the shaft and pawl without the torsion spring or gear to ensure it was seated all the way. This gave me a good look at the pawl and plate and how much the shaft could come out before the pawl fell off the edge of the plate - it only needs to move out about 5mm before it falls off! The swedge plate looks OK to me, but I took Taffy's advice and shimmed the swedge plate out with two 1mm SS flat washers that fit the screws perfectly. I used red Loctite on the screws when I put them back in. I also followed Taffy's YouTube video on installing the kickstart, and everything went without a hitch. Actually, Taffy's video was very helpful - Thanks' Taffy.

NO WASHERS (STOCK)

WITH 1MM WASHERS BEHIND THE PLATE

Before reinstalling the side cover, I made a tiny brass tube for the water pump drain hole. The previous owner has sealed it up with orange silicone, which keeps dirt out but could also force water into the crankcase if the seals fail. I filed a slight taper on half of the tiny tube, pressed it firmly into the vent hole, and added a length of small rubber hose. No dirt is getting in there now and it will still vent if needed.

The clutch basket is installed, and everything is timed. You can't see the two punch marks on the cam sprocket, but they are both aligned with the top edge of the head casting.

The side case is back on, and the kickstart works like it should. Thanks all for the great pointers.

Connecticut_FE550 · Jul 30, 2024

o6550 said:
I removed the clutch and kick-start assembly and inspected the swedge plate (see photos). Then, I reinstalled the shaft and pawl without the torsion spring or gear to ensure it was seated all the way. This gave me a good look at the pawl and plate and how much the shaft could come out before the pawl fell off the edge of the plate - it only needs to move out about 5mm before it falls off! The swedge plate looks OK to me, but I took Taffy's advice and shimmed the swedge plate out with two 1mm SS flat washers that fit the screws perfectly. I used red Loctite on the screws when I put them back in. I also followed Taffy's YouTube video on installing the kickstart, and everything went without a hitch. Actually, Taffy's video was very helpful - Thanks' Taffy.

View attachment 17220 View attachment 17221 NO WASHERS (STOCK) View attachment 17222 WITH 1MM WASHERS BEHIND THE PLATE

Before reinstalling the side cover, I made a tiny brass tube for the water pump drain hole. The previous owner has sealed it up with orange silicone, which keeps dirt out but could also force water into the crankcase if the seals fail. I filed a slight taper on half of the tiny tube, pressed it firmly into the vent hole, and added a length of small rubber hose. No dirt is getting in there now and it will still vent if needed.

View attachment 17217 View attachment 17218 View attachment 17219 View attachment 17223

The clutch basket is installed, and everything is timed. You can't see the two punch marks on the cam sprocket, but they are both aligned with the top edge of the head casting.

The side case is back on, and the kickstart works like it should. Thanks all for the great pointers.

I did the 1mm washer mod that Taffy suggested and you did. The sledge plate no longer sits flush with the case.

Were you left with this same gap that I have? See attached picture.

Is this gap ok?

o6550 · Jul 31, 2024

Connecticut_FE550 said:
I did the 1mm washer mod that Taffy suggested and you did. The sledge plate no longer sits flush with the case.

Were you left with this same gap that I have? See attached picture.

Is this gap ok?

I don't recall if there was a gap or not. All I know is that it worked.

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550 Kickstarter issues during reassembly

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