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87' TRX 350 right cover saga continues

1276 Views 9 Replies 4 Participants Last post by  shadetree
Installed cover and connected everything and when started to adjust the compression release cable I pushed on the kick start lever (by hand) and it moved (turned over engine) and then stopped. So I went to the other side of engine and the ratchet I had on the crank bolt had rotated and caught on the foo peg. Removed ratchet and went back to the kick starter, pushed on it firmly and heard a crack and then parts falling inside the case. Removed case and found the lever that rides on the cam on the kick starter shaft had broken and the pin in the cover had broken the aluminum casting where the pin fits into. Turns out I didn't have the punch marks on the cam and shaft aligned correctly. I removed the right side cover from the 86' 350 and cleaned everything up, bought another gasket and put it back together again. Chastened and somewhat traumatized at breaking a precious part (I never break stuff) I proceeded cautiously. And it is doing the same thing. Cover on, put kick starter on shaft, push with my hand, engine rolls over slightly; stops. go to other side of engine, rolls over with no problem using ratchet. Go back to kick starter; won't move. Remove cover, put kick starter back on shaft; same thing. I am sure I did or am doing something wrong. Just can't figure out what. Bike is in neutral, spark plug out and when I move the engine with the kick starter the lever for the compression release moves on the cam as it should.
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sounds like your not installing the kick start shaft right too me.
Shadetree thank-you for your promptness! I never removed the shaft at disassembly tho the splined cam must have dropped off and I mindlessly reinstalled oblivious to properly lining up the punch marks. The punch mark at the end of the spindle is facing up. Do I need to remove the shaft? If so what do I look for that is wrong?
can you pm me your phone number ?, don't post it here !
I'm putting a 350 engine back together. Got the cases put back together after cleaning everything out, and got the shift drum linkage reinstalled.

The kick start shaft didn't act like it wanted to come out, and the punch mark on it is facing straight up.

I'm curious as to what shade is going to recommend here, and what the problems is. you reallyyyyyyy wanna know what the problem was ? call it operator error here !! but hey..we all do stupid stuff !!! he was trying to kick start it over, but for some reason, it would not go all the way around..or down in this case ?. won't..WHEN YOU LEAVE THE RATCHET/SOCKET STLL ON THE CRANK SHAFT BOLT ON THE OTHER SIDE, HITTING THE FOOT REST ?!..LOL.
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Beauty :D Yup I'm sure we've all done stuff like that. No shame!
yeah..i know for a fact..i've fallen into the '' here's your sign '' A LOT !!..LOL.
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I didn't know Shadetree was going to "out" me so fast! Came on to update and confess but he beat me to it. After busting the first case I was nervous about the 2nd one. Actually what was causing the kick start lever to "stop" was the idler gear (between the kick start gear and the gear on the clutch basket) always came off when I pulled off the case. I had put it back on "backwards" to the original positioning. It doesn't look like it would make a difference but it caused enough binding that (nervously) I would go to the left side and roll the engine over with said ratchet. Now its all back together with the kick starter working properly. Big thanks to Shadetree talking me through it. I hope He has sons/grandsons to pass all his expertise on to.
thanks for the kind words !. was a pleasure speaking with ya ! :). glad ya got it going...even if it did require both of us ?!
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