Problems with the kickstart after rebuild

[rodphoto]

Hi Guys

Just rebuilding the engine and put the gearbox back together (inner and outer covers) only to find that the kick-start does not move, unless I turn over the engine using a socket on the crank.

I can select all the gears and can tell by moving the gearbox sprocket that the engine is in neutral but still the kickstart is locked.

Any ideas would be appreciated......hoping I don't have to undo it all!!!

Many Thanks

Rod

 

[grandpaul]

You may have incorrectly shimmed the tranny, or installed the needle bearings too proud.

 

[rodphoto]

Hi Grandpaul and thanks for your reply.

You may have incorrectly shimmed the tranny, or installed the needle bearings too proud.

This may well be the case.... too clarify the kickstart won't move from any amount of pressure on it, but if I turn over the engine using a socket on the crank, then I can depress it.
If I let go, it returns on the spring.

Does this sound like what you thought ?

Many thanks
Rod

 

[grandpaul]

Something assembled incorrectly, too much tension on the kicker gears.

 

[The Seeker]

Couldn't it just be the final outer case cover with the kickstarter being installed incorrectly?

There's a bit of a trick to getting it back on and aligning the kicker correctly as you do it.

Posted with TapaTalk

 

[grandpaul]

Unless you rotate the kicker back till the cutout in the gear clears the stop pin, there is no way to install the cover.

 

[rodphoto]

Grandpaul,

I appreciate your help, as this is driving me a little crazy.

I pulled off the transmission and the kickstart turns over beautifully, so does the gearbox with all gears available.

Everything is oiled and clean and smooth, however when i put the clutch and engine sprockets back on and connect up the clutch using the two plates bolted together it locks up again....

The engine won't turn unless I put a socket on the crank, then it turns fine, its a little stiff, but then all the bearings and bushes are new.

What do you think, never happened to me before, but then its been 15 years I guess, and all the previous bikes I rebuilt were 650 Triumphs and Beeza's this is my first 500.

 

[rodphoto]

Hi,
Thanks to everyone for your help with my kickstart problem,
sure enough, took it all apart again and the kickstart shaft was damaged on close inspection, managed to fix her up though and got the gearbox and clutch back on better than ever. Each time I do it I get a little better at it.
Well on the way to getting the engine back in the frame etc. Pics coming soon....
Thanks again guys

 

[Rocky]

Great news

 

[grandpaul]

Alrighty!

 

[CarlS]

This great news. Congratulations! Thanks for letting us know the solution.