1999 FC 501 Kickstart Gear Grinding

fordmanbernard · Aug 15, 2012

HELP!!!
I took apart the clutch cover to put a new shift fork in. The kick start gear came out when I pulled the cover. I am not able to get the kick start gear to stop grinding on the case and it has no tension on the up stroke of the kick arm.

I have the spring in the back side of shaft and hooked in the case. I am sure it is me just not getting something right since the kick start was working great when I took it apart.

Can I get some guidance?

kli · Aug 15, 2012

I had similar problem when i was fitting my kick starter on 501 2003

Propably you are putting spring in a wrong place.

Taffy · Aug 16, 2012

the sledge key has fallen off the sledge. you can try putting two x 1mm washers behind the sledge to bring it out a little.

also, take more care when tapping the cover on! be gentle!

regards

Taffy

fordmanbernard · Aug 16, 2012

Does anyone have a picture of how it is suppose to go in? What spring are you talking about? the big one on the back of the gear of the real small one. What is the best way to make this all go together correctly? Do I lay the bike down on the right side or stand it up?

I read something on here about a similar situation that said the kick start spring had to be wound up. Is that the case here?

kli · Aug 16, 2012

I had problem with big spring.

You have pictures and procedure how to fit it in workshop manuals from 2003 on Husaber site.
Also there are a much better pictures in manual from 2004.

I would doit with bike layed on right side.

Taffy · Aug 17, 2012

yes lay it on the right. fit the spring into the shaft and then feed the hook end of the spring into the gearbox area and get the shaft in the hole at the same time.

then fit the baby spring and sledge key. that will be up at around 1-2 o clock and everything will be loose/the shaft doing nothing.

you then put the kickstart arm on it all but the arm must face the steering head. then wind it all through enough degrees that the key goes past the left end of the sledge. then tap down and gently release the pressure. the key should slide its arse up onto the sledge and reverse itself up to the stopper on the sledge.

then remove the kickstart arm and fit the needle bearing and the gear. sorted.

if in the process of fitting the sidecover etc it all pings undone I recommend that you reverse it all and put a 1mm washer behind each sledge plate end to bring it out a little.

regards

Taffy

Flozn · Oct 9, 2012

hi,

my fe501e from 2000 had the same problem. I didn't add a washer, because i think the kickstart-gearwheel would hit the clutch cover. Instead of this I used a grinding machine (angle grinders) and removed 1mm metal from the side which looks at the housing. After grinding I straightened the surface with a belt grinder (granulation 60).
I removed as much metal as the bevel covered.
After this action it runs perfekt smooth without grinding at the housing :wink: .
Sorry for my bad English :| ...

cheers
Flo

1999 FC 501 Kickstart Gear Grinding

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