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kickstart gear grinding away my new sledge

Joined Oct 2008
59 Posts | 0+
Sarnia, Ontario, Canada
I replaced my kickstart shaft (updated version) and sledge a while back, and have only used it a couple times. I just finished putting on my Revloc clutch and I hear a loud grinding or whining noise. I took everything apart again, and I see that the kickstart gear is grinding on the sledge.

The parts manual doesn't show any thrust washers on the kickstart shaft or gear to keep it off the sledge, and away from the clutch outer basket. How do they expect the gear to not move around and grind on things? Has anyone tried putting thrust washers or shims in there?
 
suggest you check wether you can pull the kickstart shaft in and out when the cover is on. any slop? shim the shaft out towards the cover.

regards

Taffy
 
Ok, well the noise wasn't my kickstarter assembly. I took it all out and started the bike and it's still there. I'm now concerned that the outer gear on the Revloc autoclutch outer basket is not getting along with the crank and balancer gears on my bike. Has anyone come across this when replacing the outer clutch basket? The noise is a very loud, screaming, whining noise. It gets louder with engine RPM, but never goes away when riding or pulling in the clutch, etc. Does anyone have any experience using lapping compound on gears? Should I try that? The noise wasn't there until I put the Revloc on (Revloc works normally).
 
Re: RE: kickstart gear grinding away my new sledge

vwhusaberg said:
The noise is a very loud, screaming, whining noise. It gets louder with engine RPM, but never goes away when riding or pulling in the clutch, etc. Does anyone have any experience using lapping compound on gears?

STOP IT! Youre making my toes curl. :roll:
 
RE: Re: RE: kickstart gear grinding away my new sledge

i have a bike here right now with an old kickstart shaft in it (at least that's where i've found the previous ones) and i had the same trouble. the problem is that the screws are countersunk at 45d but the machined holes in the sledge are a bloody mess and go down in a curve? what were the factory thinking of?

anyway, got the drill on the job and it's better now, just countersank the holes a little further.

regards

taffy
 
It sounds like an issue with the starter sprag clutch. Did you have it apart or replace any of it's componants? It kinda sounds like a blower or supercharger on a hotrod?
 

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