starting trouble
Stellar HDF Member
Joined: Feb 2006
Posts: 3,035
Likes: 17
From: Houston Texas
RE: starting trouble
If the kickstart lever moves a little and you can feel the gear move with it, but it does not release, about you can do next is to remove the clutch.
Have you ever removed a clutch before? You have to remove the clutch basket and the engine sprocket as a unit together.
You will need a spring compressor tool for the clutch, along with a large socket, break over bar and a tool to hold the sprockets in place as you loosen (and then later, tighten) the sprockets..........pg
Have you ever removed a clutch before? You have to remove the clutch basket and the engine sprocket as a unit together.
You will need a spring compressor tool for the clutch, along with a large socket, break over bar and a tool to hold the sprockets in place as you loosen (and then later, tighten) the sprockets..........pg
Stellar HDF Member
Joined: Feb 2006
Posts: 3,035
Likes: 17
From: Houston Texas
RE: starting trouble
You can buy the compressor tool from J&P Cycles. The part no is:
630-207 Clutch puller $86.99Yeah, I know that is bad news regarding the price. You can see the picture of it if you go to J&P website. Or, I can furnish you with a pic of it too.
If you have a few tools you can make your own compressor. That's what I did years ago. I just looked at a picture of one and then built my own. Nothing to it really. You can buy everything you need at a hardware store.
I used a 3/8 x 1 1/2 wide steel flat bar for the main member. In the center of that I drilled a half inch hole and welded a 1/2-13 nut to the bar.
The steel rods you see on each end I made from 3/4 inch steel rod. These are drilled on each end and a short length of 1/4-20 all thread rod was put in each end. The inboard ends thread into two primary holes in the case. These would be the two that leave the flat bar spanning the clutch with the 1/2 inch nut centered over the clutch center. Stick a 1/2 inch all thread bolt into the nut and tighten down against the clutch, and the springs compress as you do so.
If that is too much for you to do, then about the only other way is to have a friend that has one or has access to one............pg
630-207 Clutch puller $86.99Yeah, I know that is bad news regarding the price. You can see the picture of it if you go to J&P website. Or, I can furnish you with a pic of it too.
If you have a few tools you can make your own compressor. That's what I did years ago. I just looked at a picture of one and then built my own. Nothing to it really. You can buy everything you need at a hardware store.
I used a 3/8 x 1 1/2 wide steel flat bar for the main member. In the center of that I drilled a half inch hole and welded a 1/2-13 nut to the bar.
The steel rods you see on each end I made from 3/4 inch steel rod. These are drilled on each end and a short length of 1/4-20 all thread rod was put in each end. The inboard ends thread into two primary holes in the case. These would be the two that leave the flat bar spanning the clutch with the 1/2 inch nut centered over the clutch center. Stick a 1/2 inch all thread bolt into the nut and tighten down against the clutch, and the springs compress as you do so.
If that is too much for you to do, then about the only other way is to have a friend that has one or has access to one............pg
Thread Starter
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Cruiser
Joined: Mar 2006
Posts: 145
Likes: 0
From:
RE: starting trouble
ok i got to talking to the guy i bought the bike from last night at work. an idea we were talking bought and after i got home i investigated a possibility. now i shifted the bike. now the other day when you had me shift it i rocked the bike back and forth and would only move a little before you could feel it in gear. went throught the rest of the gears this morning, only finding another issue. the bike moves freely in the rest of the gears like it is in neutral. is this telling me the gear timing is off? now if so could it be that the kick has no idea what gear it is in causing it to be locked up? as you can tell im trying everything in my will not to pull off the clutch gears. or is this gonna be a complete new problem that i am facing. by looking at the manual it doesnt look to be that hard to put back into time. the guy i bought it from originally bought it from ebay but never did anything with it. sold it to me cuz hefound out it was too big for him. so thats how i ended up with it, he also hasnt gone to this extreme like i am now.
Stellar HDF Member
Joined: Feb 2006
Posts: 3,035
Likes: 17
From: Houston Texas
RE: starting trouble
Well, the kick starter parts have no connection with the transmission whatsoever.
'went throught the rest of the gears this morning, only finding another issue. the bike moves freely in the rest of the gears like it is in neutral'
I would not get too concerned about it not going into gear yet. It may simply be that the pawl carrier or the shifter cam plate is hung up. These are the parts that move the shifter forks and change gears. Once you get the engine to spin this may go away.
Concentrate on getting the kick starter to work first. You can see looking at the diagram of parts build up I attached earlier that the kickstart has no connection with the transmission.
The starter gear engages with the starter clutch (it's called a starter clutch, but it is nothing but a ratchet gear) braded to the backside of the clutch basket.
If you have to go into the transmission later you will need to again remove the clutch.
So, find yourself the clutch tool. I know you want to avoid removing the clutch, but wishing will not help solve the problem.
Get the tool and tackle it head on...........pg
'went throught the rest of the gears this morning, only finding another issue. the bike moves freely in the rest of the gears like it is in neutral'
I would not get too concerned about it not going into gear yet. It may simply be that the pawl carrier or the shifter cam plate is hung up. These are the parts that move the shifter forks and change gears. Once you get the engine to spin this may go away.
Concentrate on getting the kick starter to work first. You can see looking at the diagram of parts build up I attached earlier that the kickstart has no connection with the transmission.
The starter gear engages with the starter clutch (it's called a starter clutch, but it is nothing but a ratchet gear) braded to the backside of the clutch basket.
If you have to go into the transmission later you will need to again remove the clutch.
So, find yourself the clutch tool. I know you want to avoid removing the clutch, but wishing will not help solve the problem.
Get the tool and tackle it head on...........pg
Stellar HDF Member
Joined: Feb 2006
Posts: 3,035
Likes: 17
From: Houston Texas
RE: starting trouble
'now before i do this could i use "c " clamps to keep everything together?'
C clamps to keep what together, the clutch springs? Not going to work if you are somehow trying to use C clamps in place of a spring compressor tool.......pg
C clamps to keep what together, the clutch springs? Not going to work if you are somehow trying to use C clamps in place of a spring compressor tool.......pg
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Thread Starter
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Cruiser
Joined: Mar 2006
Posts: 145
Likes: 0
From:
RE: starting trouble
no i looking toward keeping everything together so i dont have a big mess. dont need a million pieces all over the place. as far as taking it apart im gonna try to make one from what is laying around using your directions.
Stellar HDF Member
Joined: Feb 2006
Posts: 3,035
Likes: 17
From: Houston Texas
RE: starting trouble
My homemade spring compressor is stashed somewhere in the attic above the shop. If I can get to it I will take some measurements and do a post directed to you with the info as soon as I get the chance. That may make it easier for you to build yours.......pg