Kickstart/clutch help (late 80's/early 90's)

Hi, got a bit of a project going atm, it's a 1990 husky TC510. Bought from a breakers for £450, so far it's had a complete engine strip down and rebuild, new rings, conrod and mains etc. Getting it all back together now but still have the same problem I had when I originally got it, basically firstly the kickstart quadrant (think that's what it's called) catches on the ring gear of the clutch. Obviously this jams the engine up but it's been put together how it says in the diagrams, one washer behind the basket and one in front. Really confused about this as I can't physically move the clutch forward anymore. Next problem is the kickstart quadrant catches on the bit that holds the return spring in place, is this normal, if so seems like a hell of a design flaw. And finally the kickstart shaft is too short so you can't get the circlip on the kickstart. I should be able to modify it but am I missing something obvious lol? Never seen a kickstart like this tbh, really weird

Heres's a few pics to show what I mean:

Kickstart catching on clutch




Catching on casing



Would appreciate any help

Thanks

Your kicker shaft is installed incorrectly. In your bottom picture, looking from the inside out, the kicker shaft needs to rotate about 110 degrees counterclockwise, so that the pawl is held by the "step" in the pawl retainer (the half-circle plate metal held by the two countersunk phillps screws). Hard to explain. Somewhere on this site is a picture...

If you look at your picture of the clutch cover with the circular wear marks note the following, Using an analog clock as reference see that metal piece held on with two machine screws speading from say 10 to 2 o'clock, well that pawl thing is supposed to retract on that lump thing as the inside diameter decreases at around 1:00 or a little later. That is where it is supposed to be at rest and it moves counterclockise or anti clockise as it is operated. That may clear up some of your issues. That bike goes into the older single cam section on here the way it seems to me but a lot of parts are the same as in this section.

I have those circular marks on one of my bikes, an 1988 one and can't figure out what made them. I could figure what would make marks like that but nothing seemed in exactly the right spot to make the whole thing. I put a scratch across and it doesn't do it now. Compared to the sutff I usually take apart those gears and clutch fingers look quite close to new.

Fran

That video's completely cleared it up, can't believe I didn't realize that before lol. Well that's cleared up the first two problems, but the shaft's still too short (or the kick starts too wide) to get the cir clip on. Not really sure what I can do about that other than take a few mill off the lever. Thanks for the help.

Are you sure it's too short? Once you get that spring wrapped up correctly it sort of wants to wedge the shaft out a bit (or IN if you're looking at from the outside). Maybe you've already done this, but try putting the shaft in by itself - no O-ring no spring - and see if the circlip groove is in the right spot. I certainly haven't come across all the various parts, but I've sure thrown together a few crazy combo's of cover, shaft, kicker and so on from multiple years. Have not come across one that was too short. Yet.

yeah deffo too short, only about a mm or 2, tried every way to get it to go through far enough but no luck. I did replace the shaft as the old one was worn where someone put it together wrong in the first place so maybe that one's longer. Just started putting it back together now, it works but where the semi circle thing goes down in steps, it lets the pawl out just far enough so it grabs the cog but then slips off because it's not all way out. Hard to explain but when it gets to the second step it turns it over fine. Think there was some serious bodgery to this bike in the past lol.

You have the wrong shaft you have from the look of it have a 2 stroke shaft which was 2 piece.These were never on the 510's
There were 2 shafts fitted to the 4 stroke Huskies part # 1611 67701 up to 1991 & 1611 67702 - 1992-2004
The only difference was that the the 67702 were longer by about 2-3 mm.They are interchangable as long as you have the correct year kickstart.
Great video huskydogg: One piece of advice which saves time when putting on the clutch cover always fit with the kickstart installed as per video, the kickstart holds the shaft in place stopping the release of the kickstart return spring tension!