Help! Stumped?? Kickstart jam 98 ec250
 

Hi All,

Im stumped - need help. This is the problem:

After a recent rebuild - engine turns over on crank fine - see pic 1. All the gears turn - the crank gear the flywheel gear the clutch basket and the kickstart gears - all turn when I turn the engine,

Pic 2 - when I try the kick start its solid! When I slide the clutch basket off the kickstart and starter cog turn fine and return spring - everything. Then when the clutch basket goes back on - solid with the kickstart!

What is going on? Any help appreciated...Attachment 9130

Attachment 9131

Do the crank, clutch and balancer rotate ok without the kickstart assembly in place?

yes all rotate normally on the crank

The kick start drive is not "timed " properly.
There's a flat plate that the kick lever gear ramps on, to engage the clutch basket gear.
You can try rotating the kick start gear clockwise a couple degrees.

Assembly should be the same as listed in this manual.

https://www.dropbox.com/s/i93vw77r9k...anual.pdf?dl=0

JUST pulled mine apart 2 days ago, same thing. The shaft angles without the outer cover on and gear hits the clutch.. Put cover on and you will be fine. I was trying to determine a bearing noise and trying to turn with kickstartwe with clutch side all open and felt it jam

I've had the same before, with mine it was the little nylon spacer for the spring had indexed round so the cutout wasn't mating with the spring