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86 TRX350 kicker kicking back!

1452 Views 8 Replies 2 Participants Last post by  retro
1986 project TRX350 got it through estate sale. In process of changing electrics back to OEM.

Cycling the engine with the kick starter because the electric starter just spins. I rebuilt the starter but A side note i thot I reinserted the starter gears properly hmmm. Maybe not.

Ok anyway the kicker kicks me back鈥攂adly! It will cycle and chug鈥攑ositive i set the valves correctly. I have never had one do me like that. Anyone give me a clue?
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For a 350 to kick ya that bad its almost gotta be caused by an early ignition event doesn't it? Does the compression release seem to help any? You had the flywheel off when ya changed the stator right? So that rules out a sheared woodruff key... an' turns this into a head scratcher. I dunno!
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Its possible that the key is partially sheared then, but intuition tells me its probably not. I guess its back to checking the basics again... swap a known good spark plug into it and go from there...? After your foot and leg heal up maybe.
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Ya gotta pull the flywheel to get eyeballs on the woodruff key. That requires a puller... so unless ya have one already, ya may want to exhaust all other possibles first.

But if the one-way starter clutch turns out to be bad, as the reason why the starter motor doesn't spin the motor over you'll be in there soon anyway... If I remember right a flywheel puller costs about $15-$20 on G&H web site and 'bout the same on eBay.
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Right, unless the field magnets housing is the wrong one (or spun 180 degrees during reassembly?), or the polarity is backwards the starter motor cannot spin backwards. So that leaves two possibles... either a reduction gear is stripped or the one-way starter clutch is slipping.
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