Help! Stumped?? Kickstart jam 98 ec250

[bvacher]

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...IMG_7788.jpg

IMG_7791.jpg

[Zman]

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

[bvacher]

yes all rotate normally on the crank

[gasgasman]

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.

[gasgasman]

Assembly should be the same as listed in this manual.

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

[Banditpowdercoat]

Originally Posted by bvacher

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

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

[motopsycho87]

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