Kickstart is all messed up By rosiemoto (Read 625 times)

[rosiemoto]

I'm having a few problems with my kickstarter.

1: the kickstart lever doesn't seem to grip to the camshaft. Both are pretty rusty and I'm wondering if they're just stripped out. Or it could be that the kickstart lever's bolt isn't being tightened enough because it's stripping out... not sure where to blame.
2: 80% of the time the kickstarter gets STUCK as I try to kick it, and something inside the bike will make loud pops if it gets stuck then frees itself halfway during the kick. I hear the same loud pops when first using the electric start sometimes. I think the middle gear isn't pushing out properly?
3: When I take out everything and realign the gears correctly, as in both alignment marks facing <-- <-- , I bolt the CVT case back on and give it a kick and it just goes out of whack and gets stuck/doesn't return. So gears on correctly seems to be completely useless on my bike.
4: When I put the gears on INCORRECTLY, as in both alignment marks facing --> -->, the kickstart has a huge deadzone but after about 90 degrees of dead turn it'll catch and give maybe 3 or 4 inches of kickstart I can use, so if I give it a swift smooth kick it'll start.

PICTURES: (sorry I forgot to take one of the gears themself.. but I do know the "middle" gear has a crack in it somewhere.)



Would it be worth spraying those with WD-40 and maybe like a wirebrush to get that rust off? The stripped bolt I mentioned I'll just get a new one at Ace. Hopefully it's just rust and the teeth are fine but what do you think?

Thank you!

[Alleyoop]

First the POPs is caused by a very rich condition, and that also causes low rpms which in turn causes sluggish throttle response. So your carb needs to be adjusted and or the air filter is clogged and restricting air and or both.

As far as the the kickstarter is concerned the no return is lack of spring tension and or broken gear.
But you can get new gears and springs.
Alleyoop

www.scrappydogscooters.com/125_150_4-STROKE_PARTS.html

[rosiemoto]

Sorry by pop I meant CLANK like metal hitting metal.

[Alleyoop]

I think you have a problem in the kickstarter gears and they are making the noise.
Since it makes the noise when electric started take the cvt cover off and see what is banging against something.

[rosiemoto]

I realigned my kickstart gears correctly (I had it backwards) about a week ago and it hasn't made any clacking when electric starting since.

I notice now the welded part of my kickstart "crankshaft?" likes to butt itself onto the middle gear...whatever gear that's called. I tried to temporarily put the kickstart lever on to wiggle the gears back in place , but soon as I put on the CVT cover I hear it butt itself back on there. Sneaky thing.