kick start not returning

[swissdean]

Happy new Year, over the break i replaced my snapped kickstart shaft for my LI150 (S3). Replacement set up is: new kickstart shaft (casa version..this one: http://www.scooter-center.com/de/produc ... 4*1*1*1*16) , and new MB style kickstart piston..

On first assembly she started fine but then I had massive kick back and limited travel..so stripped apart and found some wear on top of inner shaft (very common i have since read with blend of either grinding down or using special tool to cut out some chainsase material). Realised that I had arranged circlips incorrectly on outer shaft and had too much internal travel. So reassmbled and made sure inner bush in fully tight, pulled through kickstart shaft and assembled circlips properly, all was very flush on both sides of the shaft and adjusted piston chaincase guide so that the kickstart engages just below the rubber stop...all looked and felt spot on

On rebuild, first kick, kickstart stuck down (ignition not on, as i was testing out to make sure all ok), flipped it back up with gentle lift of shoe and on each repeat kick the lever is still sticking down...I've searched on here and looked in Stickys book but cannot find any suggestions what may be causing this?

any suggestions out there on what to do/look for when i strip it back down..?

PS, i have not put any oil back in the engine as yet (guessing I may be in need of a follow up stripdown)) , sharing this info, but i am not sure that would make any difference re kickstart return, only other thought is a installed the big spring a different eway around as there was a bit of flattening/wear on top so now have this end facing the chaincase?

Thanks

[HxPaul]

Have you got a standard style exhaust (clubman or other that fits under the floorboard as a standard exhaust),if so the stop on the kickstart may be catching on the tailpipe of the exhaust,a common fault and one that I cure by grinding or sawing the bumpstop of the kickstart until it clears the tailpipe.

[P D: SC Chester]

I had a similar problem on my GP, when you put the casing back on, you need to push the kick start down and locate it in the bottom of the guide.
Hope this makes sense, the only way I can explain it in layman's, is: the kick needs to be under Tension, so when you kick it, the spring makes the peddle return .

[HxPaul]

I had a similar problem on my GP, when you put the casing back on, you need to push the kick start down and locate it in the bottom of the guide.
Hope this makes sense, the only way I can explain it in layman's, is: the kick needs to be under Tension, so when you kick it, the spring makes the peddle return .

Only on GP's

[P D: SC Chester]

Apologies......

[swissdean]

Thanks all, will check on both counts, even though LI , will try all fixes for now..i don't think it's catching on the exhaust but a good one to check

[Wack]

You will probably find that if you fit the return spring the wrong way round, i.e. the kinked end into the casing ,the spring becomes coil bound on the casing spigot ribs. I'd suggest taking the casing off and working the kickstart down and see if it binds, if all ok and it springs back to the stop then check the piston pin is not catching on the main casing or the ramp.

[Ivor the engine]

Hi,
Split casing and check on the top of the kickstart shaft for wear / signs of interference with the top clutch plate. Common issue with new kickstart shafts.
If there is wear, grind down the area slightly.
Regards,
Ivor.

[Delboyli150]

Had same problem, just recently. Brought a cassette clutch from AF and clutch was not engaging correctly, took of side case and you could see a score all around the cassette case and on the actual kick start shaft itself. Spoke to friend at local club, he mentioned return spring being on wrong way round (it was ) and to check this plus the kickstart shim and circlip on outside, which was fine. Use a1.00mm gasket on casing as well. I felt tip the clutch and the kickstart axle and rebuilt, just using 1/3 of side casing studs/nuts. Kicked over a couple of times and took side casing off again, no scores felt tip intact so working good.

Phoned Ben at AF, where purchased Cassette clutch from, who talked me through how to check clutch being engage correctly when out of engine, all good.

Check return spring.
Check kickstart shim/circlip.
Use a 1.00mm side gasket.
Use felt tip!

Happy days.

Now to get on with the next problem.......

[swissdean]

I'm embarrassed to say I solved this by realizing the kickstart was ( just) catching on the Allen bolt on the exhaust supporting bracket... literally 3-4 strokes of a file and all was sorted... sometimes it pays to look for the obvious things I guess