Brand New GG 300 Sounds Like It's Going to Self Destruct

[GMP]

Mark,

Your problem sounds like the spring guide was not installed indexed correctly and the spring not completely seated.

 

[wence]

Glenn,
You are correct as the kickstart would not return after kicking, but at the time of the noise the lever was up in the correct position.
Thanks Mark

 

[Vurelis]

You almost certainly have a starter problem from the way you described it. The starter has 2 springs: one to engage the starter gears and another to return the starter lever to it's stored position. On my 07 gasser the engagement spring was weak and wouldn't always push the gears together quickly and hard enough to engage. I suppose you could stretch the spring to add preload to it to fix that problem but your problem seems more likely to be the return spring. The end of the return spring is bent at a 90 degree angle and that fits into a hole to anchor the spring. During assembly the end of the spring may have come out or the spring may have needed one more turn to preload it properly before sticking it in the hole. Check your starter lever the next time you hear the racket and note whether or not it is in the fully restored position. If it is not you have found your problem. If you have the noise when the starter lever is fully retracted the problem does not lie with the return spring.

 

[wence]

Mark,

Your problem sounds like the spring guide was not installed indexed correctly and the spring not completely seated.

Glenn,
Just to update from long ago.
When I pulled it down again the end of the spring had snapped inside the plastic bit, therefore spring would not locate correctly.
Cheers Mark

 

[GMP]

Makes sense, glad you found it.