Reassembling the kick starter

Hair · Jul 10, 2009

04 FE 650
My kick-starter got away from me the last time that I removed the side cover. Now I am trying to get it all put back together.
And I have a couple of questions.
1, Do I need to preload the main kick-starter spring? If so how many loops or how much preloading?

2, Indexing the main shaft. The main kick-starter shaft seems to be getting miss-aliened the stop can somehow end up on the motor case. When this happens, the leaver is hard to push and it leaves a mark in the case. How do I get the indexing correct?

ned37 · Jul 10, 2009

per the "owner's doc!" accessed at the left side of the page:

"Kickstart fitment
Remove the outer gear and bearing for now so that you have just the splined shaft complete with 'keyhole' ratchet (sledge key) and it's tiny spring fitted. The diagram in the parts manual shows the kickstart spring the wrong way around! So you need the straight pointed end to face away from the bike at your face!

Fit the straight part of the spring into the tiny hole in the kickstart mechanism and then fit the hooked end into the engine case feeding it all in as one. Leave the body of the splined shaft OUTSIDE the crescent and re-fit the kickstart arm at 11 o'clock. Start winding the unit clockwise until the 'keyhole' shaped ratchet piece goes past the 'stop' of the crescent plate. Now, holding the sledge key 'closed', press the unit down into the case using the kickstart lever to 'wobble' it down. Release both the keyhole and the kickstart lever. The unit will turn itself counter-clockwise and rest against the shoulder of the crescent. Now hold the gear down while you remove the kickstart arm and you're ready to fit the bearing and gear on. Because the keyhole is 'closed up', the gear will drop on! "

Hair · Jul 10, 2009

Thanks that is exactly what I was looking for.

Now if I could only get my hands on a dog spring. The little guy took off on me. I can't find it anywhere. It was a little messed up anyway.

Or if someone knows the size of that spring. That would help too.

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Reassembling the kick starter

Hair

ned37

Hair

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