Kick start ratchet assembly

[rpr851r]

Hello All,

I am in the process of putting my CL77 engine back together and buttoned up the cases last night. After getting everything torque and installing the kick start internal stop I turned the main shaft while holding the kick start against the stop and can still hear the ratchet mechanism. Is this normal or should it be silent? At this point the trans doesn’t have any lube beyond what I used for assembly. Also the paw in the ratchet mechanism looks to be new, the gear looks to be in nice shape, and the 14mm bushing is tight.

Thanks,
Rich

[davomoto]

Rich,
Are you rotating the kick shaft clockwise? If so, you should not hear the pawl ratcheting. When rotating the kickshaft forward, you can feel it hit the stop and release.

Davo

[rpr851r]

Hi Davo,

Well that’s a bummer, I did rotate and hold the kick start shaft clockwise hard against the stop. It does release the mechanism and allow me to turn the mainshaft but I can still hear/feel the paw bumping along inside the gear which I didn’t think was right.

I will take a look and make sure the kickstart shaft was indexed correctly before I installed the stop bolt. After that I will look at all the stop bolts I have to see if there are differences between any of them before I split the cases to take a look. Any other suggestions?

Thanks,
Rich

[Snakeoil]

The kickstart shaft tends to turn counter clockwise on it's own when the tranny is turned and even turns a bit on it's own if there is no kickstart return spring on it.

First, turn the kick starter shaft CW before you put on the cover. Hold it for a moment and when you let it go, make sure it stays there. Then, when you install the side cover, rotate the kick starter lever ccw to about 9 o'clock and then slip it over the spline on the shaft. When you have the cover in place, the kick lever in the folded position should be just over the forward corner of the side cover. If not, take off the cover and adjust where you have the lever when you engage the spline and try again. Pictures in the service manual show you where the lever should be when at rest.

If you don't index the starter lever, it ends up resting against the case and prevent the shaft from returning to it's correct position for a running engine.

regards,
Rob

[rpr851r]

Hi Rob,
I am not at the point of putting on the engine covers yet. I am just mating the cases now and noticed that my kick start ratchet mechanism makes noise when I torque the kickstart shaft against the internal stop and turn the main shaft. I have an issue somewhere with the kick start ratchet not fully releasing the paw so it doesn’t make contact with the gear when the main shaft turns. I wish I was at the point of putting on the kicker cover and indexing the kick start lever.
Regards,
Rich

[davomoto]

Rich,

You are holding the shaft while turning the main shaft correct?

Davo

[rpr851r]

Davo,

I am holding it against the stop as hard as I can while I turn the main shaft. After looking at the parts manual and thinking about it some more my money is on the bushing not being as tight as I thought. I will get to the bottom of it tonight.

Rich