SEBanshee Posted January 2, 2008 Report Share Posted January 2, 2008 I almost have my engine all the way back together after splitting the cases, and have since put it back in the frame of the bike. I followed my Clymers manual all the way and did what it told me to do in putting it back together. I can spin the engine (in gear without the chain around the sprocket) with the flyweel, and everything seems to be working fine. I put the kickstarter shaft in the way it told me, and put the case cover for that side on, and put the kickstater on the shaft. I tried kicking it, but it will not budge the engine. I'm at a loss. I can turn the engine over fine if I grab the flywheel, but the kickstarter will not do it. If anyone has any ideas, I would be greatly appreciate it. I think I've had more bad luck than good and just want to get it back together and finished. Quote Link to comment Share on other sites More sharing options...
sheerider1026 Posted January 2, 2008 Report Share Posted January 2, 2008 never heard of this one?? i would say pull the clutch cover back off and the problem will probably be obvious.. its pretty simple on how it works.. i would pull the cover and recheck it. Quote Link to comment Share on other sites More sharing options...
fastrthnu Posted January 2, 2008 Report Share Posted January 2, 2008 Does the kicker move at all? or is it jammed? Quote Link to comment Share on other sites More sharing options...
SEBanshee Posted January 2, 2008 Author Report Share Posted January 2, 2008 Does the kicker move at all? or is it jammed? It moves down like it should, but its like the gear isn't catching, and therefore it doesn't spin the engine. I checked it many, many times and the gear moves out like it should, but its just not turning the rest of it. Quote Link to comment Share on other sites More sharing options...
HotCarl Posted January 2, 2008 Report Share Posted January 2, 2008 post some pics, it will make things go a lot faster. Quote Link to comment Share on other sites More sharing options...
dawarriorman Posted January 2, 2008 Report Share Posted January 2, 2008 Sounds like you might be missing the idler gear that sits between the clutch basket and the kickstarter gear. Quote Link to comment Share on other sites More sharing options...
SEBanshee Posted January 3, 2008 Author Report Share Posted January 3, 2008 Sounds like you might be missing the idler gear that sits between the clutch basket and the kickstarter gear. Nope, its there. I'll get some pics up soon. Quote Link to comment Share on other sites More sharing options...
fastrthnu Posted January 3, 2008 Report Share Posted January 3, 2008 Nope, its there. I'll get some pics up soon. make sure there is a circlip and washer holding it on,.. (the idler gear) It may be tilting out when the kicker gear comes out. Quote Link to comment Share on other sites More sharing options...
dawarriorman Posted January 3, 2008 Report Share Posted January 3, 2008 make sure there is a circlip and washer holding it on,.. (the idler gear) It may be tilting out when the kicker gear comes out. That would be my next guess too, although I had my circlip fall off while riding. Kept starting the whole time. Never once did it miss. I only realized something was wrong when I went to change the oil and a giant clump of shavings was stuck on the drain plug (magnetic drain plugs are life savers). If all the pieces are there, there really isn't any way it won't work. You push down on the kicker, it spins the gear while kicking it out. Which engages the idler gear which is always meshed to the clutch basket. From there the motor will spin. If all the pieces are there, then you must have it assembled wrong. Snap some pics. Quote Link to comment Share on other sites More sharing options...
SEBanshee Posted January 4, 2008 Author Report Share Posted January 4, 2008 That would be my next guess too, although I had my circlip fall off while riding. Kept starting the whole time. Never once did it miss. I only realized something was wrong when I went to change the oil and a giant clump of shavings was stuck on the drain plug (magnetic drain plugs are life savers). If all the pieces are there, there really isn't any way it won't work. You push down on the kicker, it spins the gear while kicking it out. Which engages the idler gear which is always meshed to the clutch basket. From there the motor will spin. If all the pieces are there, then you must have it assembled wrong. Snap some pics. Ok. I'll get some pics tomarrow. Quote Link to comment Share on other sites More sharing options...
SEBanshee Posted January 6, 2008 Author Report Share Posted January 6, 2008 Ok guys, this is what it all looks like after I put it back together. If anyone wants to see better/more detailed pictures then just let me know. Quote Link to comment Share on other sites More sharing options...
fastrthnu Posted January 6, 2008 Report Share Posted January 6, 2008 Did you check that idler gear to see if the circlip and washer were on it. Its the one the kicker gear slides out to and turns halfway behind the clutch basket. Try to put the kick lever on there and hold it straight and see if its lining up with the idler gear. Otherwise you just prob have to turn adjust that kicker gear to the left ot right a notch. Quote Link to comment Share on other sites More sharing options...
spurdy Posted January 6, 2008 Report Share Posted January 6, 2008 Put the kicker on the shaft with the cover off, rotate it down slowly and watch what happens. Apply pressure on the kicker shaft toward the case so the assembly doesn't come out of the recess. You should be able to see how it works and what is wrong. Quote Link to comment Share on other sites More sharing options...
jmd0346 Posted January 6, 2008 Report Share Posted January 6, 2008 Might not have the spring wrapped tight enough. Spin it over one more time and then hook it and see what happens. Quote Link to comment Share on other sites More sharing options...
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