Floppy kick start after rebuild

[Thompo]

Hi folks,

Just finished replacing all bearings and seals in the engine, 2011 250.

Built it up and cant get the kickstart lever to sit properly.

Previously the lever seemed to rest on something to stop it going too far forward and hitting the exhaust/clutch case when not in use.

Now it is rattling off the case/exhaust

What have I missed?

 

[Jakobi]

From the pics it looks like you've put it on a spine forward from where it was.

 

[Thompo]

I think i tried it back and forward and few splines, will pop it off and double check.
The problem seems to be it is rotating forward past the point where it should stop.

 

[Jakobi]

Removing the kick starter as a whole from the spline shouldn't influence it's range of travel in and out at all.

If you mean its flopping back and forwards and lacking tension that way, then you didn't put the spring on the gear set correctly. I can dig up some pics to help but you'll need to remove the rhs engine cover to make access.

 

[Davehuge]

What I would do...

Remove the kickstarter lever and the shaft should rotate clockwise until it hits its stop. Then replace the lever in the position where you want it.

As Jakobi says... if the shaft isn't been turned hard against its stop by the return spring, then something is out of place and you need to remove the right side gearbox cover. It should be quite obvious to see.

Good luck, Dave.

 

[Gasser Nate]

Gassers do not have punch marks showing where to put the locator for the return spring perch like every other manufacturer in the world unfortunately. I usually scribe them when removing but it does sound like you need some more tension on the spring as said above...

 

[Jakobi]

For reference, this is where I set the spring at rest. Took some effort to bring it right around but the kicker recoils all the way as expected.