kickstart stops dead/meets resistence at begining of stroke

[lammysilver]

Friend has just fitted his side casing to his Winter model and discovered a kickstart prob!!!

Engine moves freely by hand with side case removed, with piston traveling as it should etc.

Kickstart moves/travels as it should in side casing when removed from engine.

However... when engine is bolted together the kickstart stops dead imediately, didnt want to force it through risk of damaging it!

Kick start ramp has been adjusted to stickies manual's spec.
* The kickstart ramp is a 3 bolt fastening, open ended version (LI 3?).

Any suggestions greatly apreciated!!!

[carlos fandango]

bit of an obvious suggestion, but its no catching on the exhaust tail pipe is it ?

[lammysilver]

Nah def not catching on the exhaust

[WINTERMODEL150]

Hi,whats been done to the engine to of removed the side casing?let me know and i will see if i can help.

Dean.

[J1MS]

Anyone???

Me, I think it will be a problem with the side case assembly, but what it is I don't know.

[lammysilver]

Thanks for the response guys:

Wintermodel150 Dean- My friend has had it for about a year now, dry stored while he's been away working. Its almost finished (looks fantastic!), we went over it earlier as he's completing the build to sell it and buy a 125 special he has been offered (this is a 150 and he only has a cbt).

So in answer to your Q, nothings been done as such, we were just re-assembling as he had just got the side case back from being blasted.

[WINTERMODEL150]

Hi,have you by chance put a new kickstart shaft in as the late gp style type are thicker and the side casing needs machining down to suit ,otherwise it can get locked up when engaged,also make sure that you have shimmed the shaft correctly and the outer circlip is in the correct groove,if not then the shaft will sit further into the gearbox causing teeth to jam on the face of the first gear.

Let me know how you get on.

Dean

[joey]

...new shaft[?} catching on clutch...check for marks and grind shaft......

[mark]

this is how close they run to the clutch

kickstart clearance by mark & anne's photos, on Flickr

kickstart clearance by mark & anne's photos, on Flickr

[WINTERMODEL150]

Nice pics Mark,they do run really close but hey thats really tight in there!!