Welcome to the forums.
while I was it it replaced the kickstart assembly cause it wasnt working....it would just kick down and not spin the motor
I doubt if anything was wrong with the kickstart assembly. What usually causes the engine not to turn over when trying to kickstart, is the one-way clutch bearing goes bad. It is located on the inside of the centrifugal clutch. It is also what allows you to have engine braking.
upon reassembly when i start the bike the ratchet mechanism is clicking really loudly until i put it in gear and then it stops.
Sounds like you put the kickstarter assembly in wrong. Those are tricky to put in if you've never put one in before. It's easier to put the kicker back on the kickstarter shaft to put it in and then you can take the kicker back off to put the side cover back on. You have to hook the big spring and then wind it clockwise just a little before pushing the shaft down into the hole where it seats and meshes with the gear. It's hard for me to explain, but there's a piece bolted just to the right of where the shaft goes, it's called a ratchet guide. There's a ratchet that sticks out toward the right on the shaft that has to catch on the ratchet guide and then when the spring pulls the shaft back the ratchet rides up on the ratchet guide and raises the teeth up on the shaft so the teeth don't hit the teeth on the gear all the time. That is what's happening when you hear the clicking. Then when you kick the kickstarter, the teeth go down and catch on the gear and it turns the shaft.
Most 4-wheeler problems are caused by a loose nut connecting the handlebars and the seat!!
You only need two tools in life -- WD-40 and duct tape. If it doesn't move and should, use the WD-40. If it shouldn't move and does, use the duct tape.
Last edited by Helmut; 07-18-2010 at 03:01 PM.