Kickstart trouble

[monkfish]

Bin havin a bit of a do with my kickstart. First of all it sounded a bit noisey so I took a look and everything seemed ok so I put it back together and first kick the kickstart didnt return. I stripped again to find the kick gear (2) had moved through and past the kickstart idle gear and so not allowing it to return. This time round I noticed that the oil seal (7) is missing. Am I right to assume that this seal sits between the spacer (5) and the inside of the case and so stopping any float of the kickstart shaft.
Cheers Andy.

[oldelsieboy]

Apr 16, 2010 1:21:45 GMT 1 monkfish said:

I noticed that the oil seal (7) is missing. Am I right to assume that this seal sits between the spacer (5) and the inside of the case and so stopping any float of the kickstart shaft.
Cheers Andy.

No, the oil seal locates in a recess on the outside of the casing.

OEB

[monkfish]

ok, I have the seal, anything else I should look for before i put the case back on

[Norbo]

Just make sure you put the spring locating peg in the correct place or it wont return as it should. and may make some ratteling sounds .

[monkfish]

not sure what you mean Norbo the outside of the spring goes around the stopper at about 11oclock, the inside sits in the nylon spacer at around 12oclock. Like this


I think the problem that I have is that the nylon spacer is floating up the shaft

[monkfish]

I got the grip spring located into the case at about 8 O'Clock in the hole with semi circular wall around it. I'll build it up again in a bit when my pedigree head has subsided ;D

[carlos]

Apr 17, 2010 3:21:39 GMT 1 garyrdrobbo said:

At the rear of the gear...item "3" make sure this grip spring is located correcty into the alloy cases it self...there is an obvious place but there is also various other places it can go and causes the gear to not engage properly once the kickstart is used....

gaz

I bought a TZR125 once, non-runner, where itme 3 was missing all together, costs less than 2 quid new from Yamaha, made 200 quid profit on the bike! KERCHINNNGGGGGG

[monkfish]

Turns out that it was the kickstart lever that was rattleing cos I built it back up today, started it up and the rattle was just as bad, so I took the lever off whilst it was running at it instantly cured the noise. Looks like my kickstart lever is shot, the ball appears to have been peened into its housing so that it never makes contact with the lever, allowing the lever to swing around unhindered. It looks like an NK Racing lever that is mated with the original knuckle but its a really sloppy fit. Anyone got a spare lever?