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87' TRX 350 right cover saga continues

1285 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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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?
the truth hurts

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.
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