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Old 07-18-2010, 03:33 PM   #1 (permalink)
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kickstart trouble..help needed

Redid the top end on my 96 300 4x4 and while I was it it replaced the kickstart assembly cause it wasnt working....it would just kick down and not spin the motor.....upon reassembly when i start the bike the ratchet mechanism is clicking really loudly until i put it in gear and then it stops. Only does it in neutral and not in gear although i have not ridden the quad yet. Any ideas on why this might be happening? thanks in advance for the help!
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Old 07-18-2010, 03:51 PM   #2 (permalink)
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Welcome to the forums.

Quote:
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.

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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.
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Last edited by Helmut; 07-18-2010 at 04:01 PM.
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Old 07-18-2010, 03:57 PM   #3 (permalink)
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Here is the installation procedures as described in the repair manual. They will probably be a lot easier to understand than they way I described it. LOL.

Click the image to open in full size.
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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.
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Old 07-18-2010, 04:05 PM   #4 (permalink)
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thanks for the fast response. I think what i didnt do is align the ratchet with the ratchet guide. Is this what you were saying? And for curiosity sake...why doesent it do this when in gear....sorry....dont really know the theory and operation of the mechanism.
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Old 07-18-2010, 04:10 PM   #5 (permalink)
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Quote:
I think what i didnt do is align the ratchet with the ratchet guide. Is this what you were saying?
Yep, that's what I was trying to say.

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And for curiosity sake...why doesent it do this when in gear
That's a good question. I don't really know why it doesn't do it in gear, that's strange.
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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.
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Old 07-18-2010, 04:10 PM   #6 (permalink)
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ok...my i noticed that when i start the bike it actually pulls the kick start down as if i was on it. Thats the rachet not being lined up with the guide i believe. Thanks again!
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Old 07-18-2010, 04:15 PM   #7 (permalink)
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The one-way clutch bearing, #27 in the diagram below, is what's causing the kickstarter to not turn the engine over. It also allows you to have engine braking. Have you noticed that you have lost engine braking when going downhill? Usually when they start going bad, when going downhill, the ATV will fill like it jumps out of gear and it feels like it's in neutral. When it does this, you can bump the throttle and it will catch and hold back again.

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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.
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Old 07-18-2010, 04:17 PM   #8 (permalink)
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Originally Posted by bwy233 View Post
ok...my i noticed that when i start the bike it actually pulls the kick start down as if i was on it. Thats the rachet not being lined up with the guide i believe. Thanks again!
Yeah, the teeth are staying engaged all the time. When lined up properly the ratchet guide will hold the teeth up away from one another and it only lets the teeth on the shaft and gear engage when kicking the kickstarter forward.
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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.
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Old 07-19-2010, 09:05 AM   #9 (permalink)
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Sorry to thread jack guys, but I pulled the output shaft far enough that it won't shift properly and the kickstart does not feel connected. How do you get to the gears to get everything lined back up? Thanks.
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Old 07-19-2010, 12:41 PM   #10 (permalink)
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Quote:
Originally Posted by montec View Post
Sorry to thread jack guys, but I pulled the output shaft far enough that it won't shift properly and the kickstart does not feel connected. How do you get to the gears to get everything lined back up? Thanks.
What are you calling the output shaft? Are you talking about the shifter shaft?
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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.
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