Kick start gear issue By bohman731 (Read 1,174 times)

[bohman731]

Hey guys. I just bought a 150cc gy6 Chinese scooter last night and I'm trying to get an issue sorted out. I had one of these a few years ago but sold it and I'm trying to refresh my memory on everything. On the kickstarter gears, the most forward gear seems to be not lined up with the gear just behind it. Before I tear into everything do you think it can just be adjusted inward to lineup or should I be worried about a different issue? Picture below kind of shows the problem.

[cyborg]

looks like to me the crecent gears teeth have been chewed pretty good and also looks like the driven gear has some damage too,,,,looks like a new gear set to me ,,,i'm sure alley will chime in here ,,,

[Alleyoop]

Cannot see much from your picture but it should look like this:
Alleyoop

[cyborg]

i blew that pic up 4x over size,,,the pinion gear on the crank has lost about 3/16ths of an inch on the inside face and the middle gear has lost quite a bit of tooth tip in that three gear train,,,,and there's metal chips everywhere,,,something is not right that is for sure,,,return spring broke or not installed correctly?

[bohman731]

If the gear on the crank ends up needing replaced, can I replace it by just removing the variator and getting to it that way?

[tvnacman]

looks like the starter gear was run all the way back to the cover and that is where the shavings are coming from. Did you use an impact gun to tighten the variator nut?

John

[bohman731]

I haven't touched the scooter yet besides taking the cover off to inspect this

[Alleyoop]

May 1, 2015 16:09:21 GMT -6 bohman731 said:

If the gear on the crank ends up needing replaced, can I replace it by just removing the variator and getting to it that way?

Yes to replace the Gear on the Crank you need to take the Variator off.
Alleyoop

[dmartin95]

Ok, SO I majorly F'd up.....

I thought the kick starter gear had to be pressed on.

What I did was put the gear on the crank, then used the boss and a large bolt as a shim to come up past the splines about 3~4mm..

I then got the original nut and put it on the threads... Got a breaker bar on the other side of the crank to hold it in place...

Hit the variator side (the variator was not installed for this) with the impact...

I hit it too much apparently and stripped the crankshaft thread ends right out... The real kick in nads? In the process I got gear so tight, when I went to remove the kick starter gear, I had to break out the gear puller.

------------------------------

What is everyone else's method for installing the KS gear?

[bohman731]

Alright so I got it apart and I can't seem to get the gear off. Do I need a puller? Or is there a way I can work it off without one?

[bohman731]

Bah it posted it upside down. So so keep that in mind.

[Alleyoop]

You can use several things:

[cyborg]

i think the 2 long jaw puller in Alleys last pic will do the job nicely,,,if you dont have them most auto parts store loan them for free when you leave a deposit,,,,,

[cyborg]

take a pic and post it of the middle gear with the interupted teeth,,i'm sure that thing is mangled,,thats what tore up that pinion gear,,,Hey Alley you think the return spring for the kicker failed (broke ) and let the gears keep touching while it was running?,,,and please get some carb or brake cleaner and spray that whole area down and get those metal bits out of there,,,it's buggin me,,,,(sorry i was channeling my father there)

[tvnacman]

I would look at the return spring did it break or slip from the bolt down.

www.harborfreight.com/bearing-separator-and-puller-set-93980.html


John