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MEGA KICKBACK!!!!!

Joined Jan 2007
89 Posts | 0+
Ayrshire, SCOTLAND
Hi guiys,
Just bought a 2000 FC600 a couple of weeks back.
The bike was going really well and was quite easy to start until the kickstart-operated decompressor cable snapped. :(
When the cable snapped it became almost impossible to kick the bike over - the lever was barely budging even with my full weight (100kg) on it!
I've fitted a new de-comp cable and the bike seems to kick over easily again, but when trying to start it, the engine kicks-back very strongly, cracking the kick-start lever back with a bang and knocking the hell out of my foot & leg.
I've not managed to re-start the bike due to this kick-back and I'm concerned that if I keep trying it it'll break the kick-start mechanism OR my leg!!!!
I've not got a clutch-mounted de-comp lever, it's kick-start only.
Where should I start? :?
Cheers,
Ross
 
Hi Ross,
Do yourself a big favor and install a manual decomp lever and cable.
Dump the kickstart unit. (Note the new bikes are minus the kicker actuated cable.)

Kicking back will likely lead to the following:
shaft.jpg


Regards,
Dale
 
so much kickback makes me think that perhaps the valve adjustment should be checked.also i am not that big of a fan in relying on only the manual decomp system i feel it is good to have both.one day i was riding a bike that had the auto decomp that works with the kicker removed and had the e start removed also .well all i had was the manual decomp that is mounted on the master cylinder.what do tou think happened?as a result of a crash the tab on the mastercyl broke off that holds the decomp lever.it was a real challenge getting that bike to start the rest of the day.if no hill was avail ,one person would pull on the end of the cable with their fingers while i would kick the bike over.made for an unforgetable day!dan
 
The bike was starting and running perfectly before the kickstart de-comp cable snapped.
All I have done is simply replace the cable.
I've adjusted the cable so the de-comp mechanism on the head has the reccommended play (2mm +/-1mm).
When first trying to re-start the bike nothing much was happening, so I gave it a couple of handfuls of gas.
By doing this, do you think I may have flooded the engine and could this be causing the bike to misfire / kick-back when kicking it over?
I've not got the spark plug tool to take the plug out and check if it's flooded - I'm ordering the tool from DCR today.
Is there any mechanism in the kick-start which could not be dis-engaging properly, thus causing it to kick-back when the engine fires?
I don't want to shear the shaft as per lineweaver's photo!
Cheers,
Ross
 
Spoke with the guys at Dave Clarke Racing and they reckon it's a worn part in the kickstart mechanism which is preventing it's full release at the bottom of the stroke.
They sold the bike to the previous owner a few months back, and it was starting to develop this 'Kick-back' problem then, but the fella who biught it never got it fixed.:evil:
I'll hopefully get the replacement parts tomorrow and have her running again for the weekend. :p
I'm getting the manual de-comp parts and the spark plug tool too, si I should be 'Good 2 Go'!
I'll let you know how I get on.
Cheers,
Ross
 
Got the parts today.
They've sent me the manual de-comp fitting for a hydraulic clutch model and mine is cable-operated!
I think I can bodge something to make it fit, though.
Another question, can i fit the manual de-comp parts AS WELL AS having the kickstart operated de-comp?
I'm desperate to get the thing going for this weekend, so I'm thinking that if it's still kicking-back on the kickstart, then I may at least be able to bump-start her whilst using the manual de-comp.
In addition to this, they've sent through a replacement part for the kickstart-operated de-comp lever (1999 wokshop manual Fig 7R-5).
Could this be causing the 'Kick-Back' problem if it is worn?
If I can't have both methods of de-compression, should I junk the kickstart-operated mechanism in favour of the manual lever only?
Does anyone have any pictures of the routing of the manual de-comp cable from the handlebars down to the cylinder head?
I can't find it in any of the manuals.
I'm desperate for some pointers!!!!
Cheers,
Ross
 
Hi RossMcNish please keep the auto cable on at all times. please look over the last
stuff you have done.You did say It started before without any trouble.You might
look over the way you installed the auto cable onto the shaft (set)screw indext
into hole in shaft?Let us know!
 
YIPEEEEE!!!!
The 'Berg lives again! :D
I got all the bits through from DCR (manual de-comp lever and cable, kickstart actuator lever) and went about tying to fit them.
The manual de-comp lever was for a later hydraulic clutch model, so I had to do a bit of bodging to make it fit, but this was OK.
When trying to fit the cable, however, there wasn't enough play attach the ends to the manual lever on the bars and onto the de-comp lever on the head, even with the adjusters wound in to give as much slack on the cable as possible - BUGGER! :x
I also couldn't work out how to fit the manual de-comp cable whilst leaving the kickstart-operated lever in-situ, so decided to ditch the manual de-comp altogether and have another go at starting her with the kickstart-operated de-comp only.
CAN BOTH THE MANUAL DE-COMP AND THE KICKSTART DE-COMP BE FITTED AT THE SAME TIME? :?
I adjusted the kickstart-operated de-comp cable tension to give the proper play an the lever.
I tried bump-starting the bike, but the back wheel would simply lock-up, even in 5th gear!
In desperation I gave her another few kicks and.... lo and behold.... SHE RUNS!
Started her a few more times without any trouble just to make sure the 1st time wasn't a fluke.
I think I flooded the bike trying to start her on the choke a few days back and this (in addition to having the kickstart-operated de-comp level incorrectly adjusted) may have been giving me the 'kick-back' problems. :oops:
I've still not got the spark plug too from DCR, but this should be arriving in the next couple of days.
Took the bike to the track today with my cousin and his mate (Cousin on Honda CR500 & mate on his Kwak KXF250).
Guess what was the only bike to make it home in 1 piece?
THE 'BERG!!! :p
My cousin snapped the chain on his CR and my mate went down, snapping one of his handlebar mounting bolts - but the 'ole 'Berg kept thudding on!
The bike started fine all day, it kicked-back a couple of times (but only weakly).
The bike seems to start OK from cold WITHOUT the choke.
Could this be something to do with the setting of the idle screw on the carb?
If she's starting and running well again, should I leave it well alone???
Sorry for the long blurb, but I'm over the moon the bike's running again!
Cheers,
Ross
 

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