Setting a kick starter spring

I got a 1987 Hisqvarna AE, first project bike. I just finished rebuilding the clutch and I'm ready to put the cover back on, which has the kick starter attached. I could figure out how to set the spring, and people tell me it's hard to do and a bit dangerous. But no one really told me how to do this though. I'm wondering if there's any tools or techniques to do this final step?

the trick is getting the pawl to sit just under the cut out in the guide so it flips out as soon as you kick it. 1 tooth too far and the gear grabs the clutch gear when it stops and belts the pawl ... it doesn't last long. 1 tooth too far the other way (sorry I should say splines on the kick starter shaft not teeth) and the pawl engages too late and barely spins the motor. there was a thread on here showing a correct position some time ago... I would go back through the main left kickers topics and see if it comes up.

you need to wind the spring back with the kickstarter and hopefully when it returns against the bump rubber, the pawl is in the right spot. I think the tech manuals might have a pic... check that out.

1o you have the 430 ae manual ?

I know you've sent me a link to one in the past. Does it explain in there?

Do a search for huskydoggg and you should find a you tube video where he shows the processes of installing the mechanism into the clutch cover. your bike is a bit newer but probably the basics still apply. Get the clutch cover fully assembled and then preload the spring some by turning the shaft. I was able to just barely slip the kick lever on the spline, use the lever to rotate the shaft back to preload the spring, then slide the kick lever completely on and let it rest on the bumper. The preload should be sufficient to provide enough force to return the kick lever back up and rest on the rubber bump stop. Start lose and with your kick lever on the splines install the clutch cover. Like mentioned above if its too loose (not enough preload) you will go through a lot of the kick stroke before the system engages and turns the motor over. Too tight you will hear some clattering in the motor when the bike is running which could potentially cause damage as mentioned above. Once the cover is on and bolted up, you can make adjustments by holding the shaft in place with vice-grips and then move the kick lever to different splines to either increase preload or decrease. Your bike probably has the coarse splines so don't be making multiple spline adjustment at one time and start lose (light preload).

I think so !

I followed the huskydoggg video and it worked perfectly. Tks, HD.

This is how I do it: Take the clutch cover off the engine and put vice-grips on the spline (inside the cover) shaft so you can rotate it. Take the kick starter off the spline shaft. Now rotate the vice-grips until you see the cam actuator begin to move outward to engage into the starter gear. Now put the kick starter back on the spline shaft at the highest point (resting against the rubber stop) and that should give you ample amount of kick and enough that you are not ratcheting on the kick start gear.