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SuperMotoMike

Joined
Aug 20, 2007
Messages
202
Location
Maryland - USA
OK, so last fall my water pump shaft oil seal failed so I got a new one and replaced it. I am just now getting around to putting the side cover on the bike. I get it all back together and go to put the kick starter back on and it doesn't line up properly. It is either too far forward and hits the clutch cover or too far back and hits the gas tank. When it is the position that hits the tank it won't move even if the decompression lever is pulled in. Of course the battery is dead so I'm charging it now. What could I have done wrong????? The bike was running fine when I took the side cover off last fall.

***EDIT*** I got the kick starter to line up correctly but I still can't kick it!

Thanks,

Mike
 
You do not have the kickstart shaft installed properly. You will have to pull the clutch cover and reseat the shaft. I always try the kickstarter once the cover is snugged down to make sure it's right. Your lucky you didnt warp the cover when you torqued it down.
 
it is just on the edge of popping off the crescent that guides the ratchet assy. whenever you pull that side cover, keep your thumb on the kicker shaft to keep it in place. there is a procedure for replacing it in the doc.
and i always follow berger, he's the only one that knows where the trail goes :wink:
 
You are goint to have to fiddel with it. Warning....it is a major pain in the *** untill you have done it a few times. As Ned said, there is a procedure in "the owners doc"
http://www.husaberg.org/wiki/index.php/Main_Page

When you pull the clutch cover off you will want to put pressure on the kickstart shaft with your thumb. If not the shaft will pop out, hense your problem. You will not see the problem unless you are looking very carefully. The difference is only like 8-10mm.
When you have it in correctly the cover will fit on flush without much effort.
 
Thanks for all the responses guys!

I got the side cover back off and have fiddled with the kick start shaft but I haven't got it yet.

This might be a dumb question... Do I have to take the clutch off to get it to seat properly or can I leave it on?

Thanks again for the help!

Mike
 
Not sure about that Mike. I had the clutch off anyway. If you do take the clutch off watch out for the timing marks, as the crank and cam gears are timed througn the clutch basket.
 
afraid you have to take the clutch assembly off mike. do the procedure that is in the doc then rebuild the clutch and refit the cover, screw in a coupla screws at the back of the clutch cover and tighten lightly. then push pull the kickstart shaft to see if the key falls off again?

if it does you have a rare problem. the answer is one of two things
1. fit a shim on the outside of the kickstart gear
2. weld a blob on the side of the key that will lightly rub against the inside of the gear but keep the key on the crescent.

there is another possibility and that is that the bush in the sidecover can be pressed down the 0.5mm or whatever you need. that will keep the gear in there tight.

regards

Taffy
 
to do it right, you have to pull the clutch. not difficult. but as loz says, watch the timing. all i ever do is to mark the clutch gear tooth where it meets the primary (crank ) gear and where the clutch meets the chain gear tooth with a marker pen (assuming it was right to begin with), then pull the clutch. when done with the kicker, put the clutch back on to align with the marks. you may need to do a little wiggling with the oil pump and starter sprague gears if anything was moved.
 
Just a thought.........

Unless I have missed it here, be sure and set the motor to TDC on compression before you pull the clutch, otherwise something is going to jump as soon as you lift the clutch basket.

You might check the repair manual for the orientation of the "dots" on the primary nut gear, and the counter balancer nut gear when the motor is at TDC on compression.
 
Dale,

All I did was take the side cover off the bike to replace the failed oil seal. I can't see how it could have got out of time by doing that. The bike was running great before I took the side cover off.

I decided to pull the entire motor (mostly because I was bored) and put it on the work bench to sort out. Anything I should check or replace while I have the motor out of the frame? If so now is the time...

Mike
 
SuperMotoMike said:
Dale,

All I did was take the side cover off the bike to replace the failed oil seal. I can't see how it could have got out of time by doing that. The bike was running great before I took the side cover off.

I decided to pull the entire motor (mostly because I was bored) and put it on the work bench to sort out. Anything I should check or replace while I have the motor out of the frame? If so now is the time...

Mike
Click to expand...

Hey Mike,

My post was in regards to the fact that if you pull the clutch itself to get your kick starter sorted. The clutch ring gear times the crank shaft position and the cam position as the counter balancer nut is what drives the cam chain.
 
Unfortunately Mike you now get to learn how to remove/replace the clutch and re-time it.
Line up the dots on the gears as per the owners doc - doesn't matter what TDC its at.
BTW get used to it cos since its your first time you'll prolly have to do it a coupla times.
A real big P-I-T-A!!!!
 

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