Kickstart fail

[bultaco4ever]

I have a kick start issue....it doesn't catch all the time. I searched a little on this forum and found this member described a similar situation.

"My kick start seems to "slip" sometimes. I have to kick it lightly until it catches. Is this normal? Its almost like I have to "line it up" before putting the foot to it or it will slip and I end up killing the top of my foot with the foot peg."

It's like I find a false neutral and kick through without moving the piston at all. My foot slams the bottom of the kicks stroke and hurts my instep.

I can bump start my bike easily but can't get it to kick start. I don't think I'm generating enough speed to the rotation. What should I look at to remedy?

[ohgood]

worn dogs on the assembly would be my guess. file them sharp again ?

[bultaco4ever]

Oh?.....you can do that?.....

[Tedh98]

Don't hold me to this, but I think that is hardened steel. Might be tough to file.

[Dekon]

You might want to check the plastic bushing in the spring. If it is not seated correctly it will do that. I went through the same thing this past winter after a full rebuild. The bushing looked like it was seated but it wasn't. Only took me three times to get it corrected.

[bultaco4ever]

I watched a YouTube video of a guy who talks about the ratchet gear on his 84 KX. He said he used a Dremel tool to lightly sharpen the cog edges. It worked for a year til he found some good replacement parts.

[ced64k]

I had the same problem on a Gas Gas 200. Worn dogs on this ratchet :



I had to remove all the clutch to access it.

[koshari]

Pain to get off. I fixed up a set with a fly cutter set up in a milling machine and had the dogs in an indexing head. The idea is to actually put a slight backcut on them so they pull in under torque rather than jump.

[bultaco4ever]

Huh? I don't get most of the terms you just used. I'm a willing amateur mechanic. Can u explain?

[Julien D]

What oil are you using in the gearbox? Some heavier oils have been known to cause the ratchet gear to slip. I have a serviceable ratchet gear set if you find it needs to be replaced.

[bultaco4ever]

10w30 I think. Save that ratchet set for me. I've started disassenbling. We ll see what we got.

[koshari]

Huh? I don't get most of the terms you just used. I'm a willing amateur mechanic. Can u explain?

a fly cutter is a tool that lets you mill flat surfaces,


and an indexing head allows you to accurately set up an object with multiple evenly spaced faces,

[bultaco4ever]

If I wanted to...where would I find these services?

[bultaco4ever]

OK ....I removed the right side cover. So, in order to remove the kick start ratchet assembly, I have to remove the clutch basket first...right?

[bultaco4ever]

Photo link

https://mail-attachment.googleuserconte ... 1&disp=emb

[Dekon]

Yes. clutch basket has to come out.

[koshari]

iirc the hex nut on the clutch basket was a real pain to remove.

[Bitteeinit]

Your search might have brought up some of my old threads. I first tried changing the spring, which didn't help. I then filed the grooves a bit which helped, but made it feel "fake". What helped best is changing my oil. I used to use 20w50, and switched to 15w40. It helped quite a bit. Still not perfect but much better. Forgot what the name is, but you could also try the old Ford oil (not available where I'm at).

Sent from my ASUS_Z00AD using Tapatalk

[bultaco4ever]

So, you went to thinner oil. I think I am already thinner than you. I forget exactly what the manual recommended but I think it was 10w30 or 10w40. I'm using one of those. I have the case off already and I'm trying to get the clutch basket nut off. I'm having a difficult time removing it so far. My little air compressor is too weak for my air impact. I made a flywheel holder that I'm going to try next and use some muscle. If that doesn't work I'm borrowing an electric impact wrench. I tried heating the nut a little with the air impact but it wouldn't let go.

[Dekon]

A Harbor Freight electric impact gun is a real life saver when it comes to working on these bikes. Zips the clutch nut right off.