I have been trying to get the side case back on and the first time the Kickstart lever goes all the way through it's stroke, the ratchet doesn't return to the home spot and then, when I remove the side case, there is a spring loaded clang as it comes off and the thing goes back. I reviewed the blow up parts list to make sure I wasn't putting stuff back in backwards... Any ideas?
Replaced Clutch 1992 TRX250x, now Kickstart won't return to the "home" position
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as your putting the kick starter back on...you have to pre-load the spring as your sticking it back in....when i say pre-load..you hook the spring on the catch thats inside the case..wind the kick starter forward..this pre-loads it..if you look on the end of the kick starter shaft..you will notice a tiny punch mark..your kick starter arm also has a punch mark on it..it should have one anyway ??....after you pre-load the return spring..line up the punch marks from the kick start arm to the kick starter shaft..before you put the side case back on..very slowly..work the kick starter as you would if you were kicking it..see if the kick starter returns to it's final spot..it if doesn't..then you still don't have the return spring set right.
Thanksfor the try, I wish I could make a video of this... Doesn't seem to be a pre-load issue. I have played with the kick shaft with the transfer gear out and it goes home every time, does the one way engagement on the start gear like it should... The punch mark and Kick arm line up and are in the home position and if assembled and start there. With the cover back on, when I give it a "partial" kick through, it engages to push the motor and returns to home, if I kick it through to the bottom, it pushes the motor and returns up short of home and like I said, when it is being disassembled, there is some sort of "relief" when the cover is coming back off and a "clang/smack" and the shaft returns to home. Confusing.
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38,589 Posts
your not getting the return spring right..it's kinda tricky..if you get the return spring in its hook place..wind the kick start lever forward..then put the arm on the kick start shaft..and line up the punch marks...the tricky part is getting the spring to hook..and the rachet part on the kick starter to get into that holding spot..and lining the punch marks all up.
Kickstart return... Got it figured out
Turns out the "cam" for the compression release was clocked wrong. I had NOT seen the punch mark on the top of the shaft and had lined it up with the kicker's punch. When I showed my brother he asked how come the punch mark was so far away, we got out a flashlight and found the cam's punch mark. That mark was 180 degrees out from the kicker's punch location. Whan the kicker shaft cycled down, the follower got hung up on the cam and that was the spring loaded clang when the cover was coming off, when the follower jumped off of the cam.
:icon_ peace::icon_ peace:
Whew!
Turns out the "cam" for the compression release was clocked wrong. I had NOT seen the punch mark on the top of the shaft and had lined it up with the kicker's punch. When I showed my brother he asked how come the punch mark was so far away, we got out a flashlight and found the cam's punch mark. That mark was 180 degrees out from the kicker's punch location. Whan the kicker shaft cycled down, the follower got hung up on the cam and that was the spring loaded clang when the cover was coming off, when the follower jumped off of the cam.
:icon_ peace::icon_ peace:
Whew!
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