kickstarter revisited

wildbill · Oct 27, 2005

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.

JoeUSA · Oct 27, 2005

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

wildbill · Oct 27, 2005

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

Taffy · Oct 27, 2005

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

regards

taffy

wildbill · Oct 27, 2005

Taffy said:
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.

Wilson · Oct 27, 2005

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.

sandskipper · Oct 27, 2005

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,

Wilson · Oct 27, 2005

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.

sandskipper · Oct 27, 2005

Wilson said:
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,

sandskipper · Oct 27, 2005

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.

Regards,

Wilson · Oct 28, 2005

You're right on the money, the picture is exactly the part I was talking about . my problem happened while riding in some big hills for most of the day, getting pretty tired, i had flattened the battery after a couple of attempts to get up, so turned around gave the beast a kick but didn't let the kicker fully disengage before I clicked it in gear and dumped the clutch the kicker flicked into position with a bang and that was that, I cleaned it up and put it together, why would you bother i think the part costs all of $6, anyway like all shortcuts didn't work, mine looked a bit worse than your photo, got the new one and no problems since, the smallest burr seemed to make it stick sometimes on the inner edge of the key.

wildbill · Oct 28, 2005

The tiny spring I seem to recall wasn`t near the kickstarter. Must have fallen out sometime before. That was when I first pulled the kickstarter. The sledge appears to be in good shape. I`am still thinking that there is to much slack some where and as Taffy said the key is not engaging the sledge. Does anyone recall just where the tiny spring went? Waiting on it to warm up a little cold outside right now. Will let you know what I find out when I start inspecting the parts. Thanks.

Wilson · Oct 28, 2005

It fits into a hole on the main shaft and pushes against the sledge which pushes it out against the inner side of the gear, when the kicker then comes back to rest position it disengages when it rests against the metal piece at the bottom. I might have the names around the wrong way.

Taffy · Oct 28, 2005

Wilson

i think your post is one of the funniest 'not meant to be funny' posts i've seen.

whatever yoiu're on can i have 1/4 of an ounce please! :lol: :lol: :lol:

regards

Taffy

wildbill · Oct 28, 2005

I checked everything over and found where the spring fits in. At home I`m a packrat :lol: don`t throw nothing away, I looked in my spare odds and ends that go to a berg and found the spring. To make a long story short I have everything back together. The kickstarter works as it should but beware the little spring. I found out it is a little tricky to get everything back in place. Thanks for the help and I think I need some of that Taffy was talking about. Will keep you posted.

logjump · Oct 28, 2005

wildbill said:
I need some of what Taffy was talking about. Will keep you posted.

Maybe Json will add this to the online store! :turn-l:
1/4 oz. Husaberg attitude adjuster.

Log

sandskipper · Oct 28, 2005

wildbill,

Good to hear everything is back in and in order. I was going to have you go to my gallery and take a peak at the kickstart shaft but looks like everything is sorted.

Regards,

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