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Kick starter troubleshooting help...
http://www.kawi2strokes.com/forum/viewtopic.php?f=14&t=3767		 Page 1 of 2
Author:  Aaron Staub [ Thu Jul 05, 2012 10:03 pm ]
Post subject:  Kick starter troubleshooting help...
Well I've put about 800 miles on my H2 since bringing it out of mothballs and it has been a love affair. Until this afternoon. Rolled it off the centerstand and when I kicked it over the starter lever finished at the six o'clock position and showed no interest in returning. I pulled it back up by hand and the lever will stop at its various detent points along the stroke, but there is no spring pressure anywhere along the arc and it will not return as high as it should (and did, prior to failure). I presume I have a problem with the spring, stop lever, or both. A quick glance at the manual makes it appear that there is no real access short of pulling the engine out and splitting the cases. Is that correct? If so, do I need to pull the top half of the motor apart or can I get away with flipping it upside down and just separating the lower and then reassembling?

Any pro tips are welcome. I'm really not looking forward to this job.
Author:  Ja-Moo [ Thu Jul 05, 2012 10:09 pm ]
Post subject:  Re: Kick starter troubleshooting help...
9 times out of 10, it's a broken spring. Yes you can fix it without pulling the cylinders. You do have to pull the clutch mechanism, and the shaft oiler, end of shaft under clutch, one phillips screw.
Author:  Aaron Staub [ Fri Jul 06, 2012 4:14 pm ]
Post subject:  Re: Kick starter troubleshooting help...
Blarg. Been spinning wrenches off and on today. Except for the oil supply to the pump and the main wiring harness, the motor is pretty much ready to come out. I presume the order of operations is to slide this slug out to the side? Is one side easier than other? Any tips on how much the assembly weighs?

I discovered during disassembly that my original nylon clutch pusher is cracked about 50% of its length. Guess I will toss that on the list of to-dos.
Author:  mraxl [ Fri Jul 06, 2012 4:46 pm ]
Post subject:  Re: Kick starter troubleshooting help...
I have found that a milk crate is a big help. Set it beside the motor and lift it onto the crate.
Author:  Aaron Staub [ Sat Jul 07, 2012 4:01 pm ]
Post subject:  Re: Kick starter troubleshooting help...
Aight. Engine is out and on the bench. Looks like the shop manual recommends a special hub locking tool to remove the clutch. Anyone have one they are willing to rent out, or recommendations on a decent one to purchase?

Also, interested in any ideas on things I should be examining or replacing while I have it this far apart.
Author:  Ja-Moo [ Sat Jul 07, 2012 4:12 pm ]
Post subject:  Re: Kick starter troubleshooting help...
Aaron Staub wrote:
Aight. Engine is out and on the bench. Looks like the shop manual recommends a special hub locking tool to remove the clutch. Anyone have one they are willing to rent out, or recommendations on a decent one to purchase?

Also, interested in any ideas on things I should be examining or replacing while I have it this far apart.


Do you have an air impact, they work great for the clutch nut.
Author:  Aaron Staub [ Sat Jul 07, 2012 4:15 pm ]
Post subject:  Re: Kick starter troubleshooting help...
Ja-Moo wrote:
Aaron Staub wrote:
Aight. Engine is out and on the bench. Looks like the shop manual recommends a special hub locking tool to remove the clutch. Anyone have one they are willing to rent out, or recommendations on a decent one to purchase?

Also, interested in any ideas on things I should be examining or replacing while I have it this far apart.


Do you have an air impact, they work great for the clutch nut.


Got one. I'll give it a shot.
Author:  BarryB [ Sat Jul 07, 2012 4:17 pm ]
Post subject:  Re: Kick starter troubleshooting help...
Aaron Staub wrote:
Aight. Engine is out and on the bench. Looks like the shop manual recommends a special hub locking tool to remove the clutch. Anyone have one they are willing to rent out, or recommendations on a decent one to purchase?

Also, interested in any ideas on things I should be examining or replacing while I have it this far apart.


You don't need a special tool, you can make one out of an old steel like I did - but a great guy on the board (who shall be nameless)told me use a penny or other somewhat soft metal between the gears to lock them and you can spin off the hub nut (thanks John). :mrgreen:

Image
Author:  Ja-Moo [ Sat Jul 07, 2012 4:31 pm ]
Post subject:  Re: Kick starter troubleshooting help...
Actually the penny trick is for removing the pinion nut off the crankshaft. He won't need to do that. The clutch tool is necessary to get the clutch nut off, that is if you don't have an air impact. I think Jessbikes sells a clutch holding tool which you will nedd to get it tight again, do not impact the nut back on.
Author:  Aaron Staub [ Sat Jul 07, 2012 4:35 pm ]
Post subject:  Re: Kick starter troubleshooting help...
27 mm was the biggest half inch socket I had. Zipped it right off.
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