Trouble with Kick Start return spring - '85 500

[Husky37]

I am having a bit of problem with the return spring for the Kick Starter.

The original one would not return the kick starter so I replaced it with another one which was in good condition although secondhand but with the same effect...

Is there anything I should be aware of with regards to refitting the spring? When the spring is located should it have some movement before the spring pulls it back?

Any suggestions would be gratefully recieved.

Stu

 

[oldhuskychuck]

if the spring was easy to install, you need a shorter one..if you made up some new swear words then your lever is in a bind..

 

[Husky37]

It was very easy to install.... there didn't seem to be any tension on the Kick start shaft at all which made me concerned that something was wrong.

Sad thing is I wreaked a gasket getting the case off so it really needs to be sorted before I go putting the another gasket on.....

Does any one sell new ones?

Stu

 

[ruwfo]

i agree

Stu,
i'd agree if the spring went on easy , something wrong.

See if this picture helps, the pawl is a pain too

Husky John

 

[oldhuskychuck]

yup, that spring and prawl is a bear, make sure you use a pre 88 kickstart shaft...
the new ones that are available are junk, and will bend.

 

[Husky37]

Hi Husky John,

That document was just what was needed. As I didn't take it apart in the first place I never saw it's position to re-assemble it.

I have done it now but I agree that you do need 3 hands.... one problem I had was that the spring when tensioned did not allow for the shaft to go fully home. I placed a screwdriver between the shaft and the spring to keep it away whilst rotated the shaft and tapped it home using a rubber mallot.

Thanks.
Stu

 

[1Tuff500XC]

Yeah, thanks for the pic, that should come in handy when I reassemble mine as well.

 

[BBAP100]

I think I made that memo and picture about 2 years ago. Mine is still working just fine. Just wait until you take the other side off and have to figure out how to put the shift spring back on.....more mind benders! Steve

 

[IMvintage]

Pre 88 shaft?

Oldhuskychuck;
How can you tell if it's(the shaft) pre 88?? cause I've got 2 of them and don't wanna put in the wrong one maybe?

 

[oldhuskychuck]

in 1991 Cagiva did a couple things..first the cheapened the shaft, and they started to make them from hard cast. and then they used 2 O rings, that meens they had to put 2 grooves in the shaft.
and you guessed it, thats were it bends and breaks..right at the that groove,.
so,, a pre 91 shaft will only have one groove, and will be hardened C steel.
they are also 2 pieces as well.
the small shaft that rides on the center of the case, that the roller bearing rides on, actually slide in the gear and outer shaft.
they are made of like metals, and guawl and each other seizing inside...
heres what i did.
on a new shaft, i drilled the hole in the outer part larger with a carbide reamer, then made a oil lite bushing from bronze oil lite, that fits tight in the hole, and the small shaft rotates inside without damaging the part...
lots of work, but it make the bike much easier to kick, and wont kick back and break the inner case if you have a failure.
to make the newer 91 to 2002 Huskys work on the older shafts and bigger kickstart levers, you will have to grind off the extra lip for the cable decomp on the older style kicker shaft.
if you dont you will never get the keeper on the end.
they made the side cover a little wider on the 91 and up left kickers..

 

[gsurge]

The return spring on my 1982 125 broke, got one at Halls but having trouble getting it back together.

 

[hva-factory]

We have all the parts for the Kickstart Mech in stock. Including the shafts.

Hope this helps!

Andy.