Kick start Mechanism

Everything_To_Xs · Posted: May 1, 2009, 12:35 pm Post subject: Kick start Mechanism

Cannot get the kickstart mechanism to spring back, before engine strip down it was working fine now i cannot get it spring back at all.

The haynes manual virtually doesnt cover it at all! useless...

Any help?

gordo · Posted: May 1, 2009, 1:19 pm Post subject: Re: Kick start Mechanism

I remember it being a tricky procedure, can't tell you how to do it.Maybe someone else, like jayel or retired gentalman, maybe 5 twins could help you.

xsjohn · Posted: May 1, 2009, 1:45 pm Post subject: Re: Kick start Mechanism

My Yamaha manual says to put the asembly partially in and rotate the shaft with the kick lever 1/2 turn counter clockwise and then push it in.........suspose you have already tried that..........they did show the spring being in the provided groove........

xsjohn

Xumi · Posted: May 1, 2009, 2:50 pm Post subject: Re: Kick start Mechanism

The problem is if you don't hold the kickstart shaft in while removing the right side cover, the return spring will come unhooked and release tension.

I did it fairly recently. The manual is a good place to start, but it takes a bit of finesse to get it to stay tensioned. It took me about 4 tries to get it right, and in the end, here is the method I used:

You'll need to:

Drain oil

Remove kick starter lever

Remove right (clutch) engine side cover

Attach kick starter lever to kick start shaft

Locate return spring hook and rotate spring to attach the hook to the metal stop.

Lock return spring hook onto metal protrusion (top left side of the assembly)

Lock the return spring tab into the notch on the lower area of the assembly
push kick starter lever approximately 180 degrees CCW (just like kicking it)

At this point the spring has tension, so do each step from here carefully, as if the spring tab comes out of it's home, you'll have to re-tension the spring again.

Push the starter shaft IN toward the center of the bike. This should seat the tab more fully.

Carefully remove the kick-starter lever while holding the kick-starter shaft in towards center of the bike.

Carefully put the right side-cover back on (and replace gasket if it is torn) and torque.

Replace kick start lever.

Test and enjoy. If you return nicely, enjoy your cold beverage of choice.

Everything_To_Xs · Posted: May 1, 2009, 3:41 pm Post subject: Re: Kick start Mechanism

Wicked! thanks guys i got it Very Happy

y beverage was the only alcoholic drink i had and that was a Cold Black thorn cider on ice! Smile

xs1961 · Posted: May 1, 2009, 3:59 pm Post subject: Re: Kick start Mechanism

As above.. Ive done countless installations over the years but still it takes me half a dozen attempts on some ... Embarassed

Xumi · Posted: May 2, 2009, 4:08 am Post subject: Re: Kick start Mechanism

Nice - glad to hear you got it, and nice choice on beverage!

jayel · Posted: May 2, 2009, 9:29 am Post subject: Re: Kick start Mechanism

xs1961 wrote:

As above.. Ive done countless installations over the years but still it takes me half a dozen attempts on some ... Embarassed

on the kickstarter or the beverages?

xs1961 · Posted: May 2, 2009, 9:34 am Post subject: Re: Kick start Mechanism

Hehe..The kickstart..I cant stand cider..Real ale man meself Wink

kingwj · Posted: May 2, 2009, 9:45 am Post subject: Re: Kick start Mechanism

Here is what I'm buying to store away today.

British Beers THOMAS HARDYS 1990 UNIT
British Beers THOMAS HARDYS 1994 UNIT
British Beers THOMAS HARDYS 1995 UNIT
British Beers THOMAS HARDYS 1999 UNIT
British Beers THOMAS HARDYS 40TH ANNIVERSARY

$80 for 5 bottles and worth every cent. XS1961 real ale needs to be on cask. A toast to British ale.

What Happened to 650rider.com?

Yamaha xs650