Strange noise coming from the kickstart shaft

[PanosK]

I changed the kickstart shaft in my S2 with a CASA .
As soon as I fired up the engine there was a strange noise coming from the back of the engine.
Took out the side casing and trimmed the new shaft as the first impresion was that the shaft was rubbing on the top clutch plate.

Painted the shaft put in place and took it out again and there is no scratch indication.
The noise is now low but still exists.
When I press the clatch and place 1st gear (clutch pressed all the time) the noise stops.

Any suggestions ?

[ROB]

first check if the kickstart shaft is completly driven in. There should be no play on the inside and outside of the shaft/casing. Maybe use a different shim washer.
Also check the bush/sleeve of the kickstart piston.
...and maybe file down a bit of the sleeve.

hope this helps!

cheers
Rob

[PanosK]

Dear ROB

There is no play in the kickstart shaft.
Kickstart piston -piston peg goes all the way back to the kickstart Ramp.

If I trim the outer bush (that goes to engine casing) will it sit closer to the casing or I will create other problems?
Is there any posibility that the new shaft (I have heard that the new ones are a bit longer) scratches the crownwheel?

[ROB]

had the same problem last week...
the piston bush was too high...arround 1 or 2mm!!!
the piston goes back completly but the bush rubs against the gears.

another thing was, that the bronze bush of the kickstart shaft was not deep enough in it´s seat.

[PanosK]

I just found this:

that is used tp machine down the chaincase.

Is there an alternative other than that method?

[paulmgreen]

Have you tried changing the kick start position on the spline...... I had exactly the same problem on a scooter this week, and it cured it!

[PanosK]

Can you pls explain a bit more.
What is the spline?

Have you tried changing the kick start position on the spline...... I had exactly the same problem on a scooter this week, and it cured it!

[paulmgreen]

The kick start fits onto the splined kickstart shaft.... undo the bolt holding the kick start on..... remove the kickstart ( having marked the position before removing it) and then replace the kick start, moving it clockwise by one position on the spline, then tighten back up and see if it cures it.

What may be happening is that the kick start mechanism is being partially operated by the kick start shaft being replaced in the incorrect position.

The spline is the ridges - star shaped end of the kick start shaft

[ROB]

i hade to file down the red section:

check as well the shim that is in the picture. there should be no play inbetween casing and shim.

[PanosK]

Following all the answers I thought that the problem should be the shaft.
So in order to spot the point that I should trim down I thought of this.

I painted the kickstart shaft black (with a tin spray) and the top clutch plate.



Then put everything back in place.
Fire up the engine for 30 sec.
Take everything out and observe.



There was still a point that rubbing on the top clutch plate.

Trim down again only at that point and the problem is solved.


Thanks for the help I hope my trick can be helpful to you