Kick start problem
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Joined: Jul 2009
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From: Denver, NC
Kick start problem
Kick start has been working fine, but now its not turning the engine over. DO NOT have a manual yet, been working on this old bike, 1985 FXWG. Waiting on solenoid for electric start. Kicker wont come back up sometimes, have to pull it. Is this more than likely the ratchet gear thats in there? I know, I know, you cant see it, neither can I til I get in there tomorrow. Just feels like its slipping and wont turn the engine over anymore. Thanks, just hoping its not the tranny, mainly hoping this isnt to expensive of a project and that it happens to others, not that Id wish bad luck on anyone, but u know.
Road Warrior
Joined: Dec 2007
Posts: 1,854
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From: Eagle River WI
Sometimes the key stock will shear on the trany main shaft The key in question is located in the kick clutch gear I've had some keys "china's best " that weren't hardened properly and would shear when kicking over the 96 CI S&S motor
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From: Denver, NC
its still catching some, feels like the teeth slip out, like the clutch gear isnt engaging all the way, or the spring behind the mainshaft gear isnt strong enough. I just emptied and put in new fluids, so it may have brought up some trash. I have to pull the kick arm up by hand, unless I put pressure on it and let go, comes up by itself then. Guess i need to go in there an find out whats going on, Found the entire kit for $105, free shipping over $100, may not need it, but, shouldnt have to worry about it much if its new. Hopefully, it may only be the spring needs tightening. I'll be back.
Road Warrior
Joined: Dec 2007
Posts: 1,854
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From: Eagle River WI
Pull the kicker cover off Look into the trany You will see a nut holding a gear on the main shaft This gear has a key inside that locks it to the main shaft Also inspect the crank gear (inside the cover) and the starter gear that is spring loaded on the main shaft under the kick clutch gear ( the gear that has the key in question) Are you confused yet !
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Joined: Jul 2009
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From: Denver, NC
not confused, thanks, thats actually the most intelligent answer I could ask for. Ive ridden almost all my life, but just lately started doing my own labor. I knew there was a key on the primary side, just didnt know there was another one. When I first press the kicker, it starts to grab, then acts like teeth are coming unmeshed, theres nothing, no turning, to resistance whatsoever for about 4 inches or so, then it starts trying to catch again. If it doesnt go all the way down, it hangs and wont return to the up position. It feels like theres nothing on the kicker shaft at all. I got my solenoid in yesterday, had put in a new plunger, the roll pin kept slipping out an hanging up the forks for the starter gear on the jackshaft with the old one, so Ive got electric start now. I need to pull the kicker out and see whats going on. IFFFF its the key sheared off, can a new one be put in? Or is that a look and see type deal? When I pulled the filler plug and looked inside, I dont see anything turning when I press the kicker, so Im thinking it may be a clutchgear. Last question, is the gear with the key pressed on or does the nut an key do all of the holding in there? Again, thanks, I appreciate the help. Not sure why, but I thought that was part of the forum thing, ya know, helping someone out. I'll pull it off, maybe over the weekend, and see what it looks like, just didnt want to do it til I at least get a new gasket.
Road Warrior
Joined: Dec 2007
Posts: 1,854
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From: Eagle River WI
If you look in any parts book V-Twin/ CCI/Jereh etc They will show you a parts break down of the 4 speed kicker The key in question is P/N 33393-50 Again maybe the key is OK ? Good luck Remove nut (Right hand thread) pull gear off ( puller might be required ) and there is the key Before 1969 there were two keys !!
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Joined: Jul 2009
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From: Denver, NC
Yes, I see the breakdown. I think theres more going on than just the kicker. Im thinking the whole shaft may have went that way, in from the pulley side. I got the electric starter work, new solenoid, rode about 70 miles and the belt is in tatters. You can see it started on one side, the outside of the pulley, like its hitting it there, which is the second indication that the shaft went in. I did hear a loud clank when I was putting that small seal in between the main shaft an the pulley shaft, I didnt hit it hard, didnt want to damage the seal, but the pulley shaft did move. Not good, not good. Somethings came loose, maybe I can pull the kicker apart and looking in there, guess it would have to go in that direction? Have you ever had that happen? Of course not, ha, no one has ever had this much bad luck with a bike.
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Joined: Jul 2009
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From: Denver, NC
what keeps the sprocket shaft from going in and out? Can it be gotten to from the sprocket side if thats where the problem is, or does the whole mainshaft and it have to come out? Lockring maybe? I didnt see anything when I put the new seal in there, just steel.
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Joined: Jul 2009
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From: Denver, NC
figured out the kicker, 5 teeth sheered off the gear, ordered a whole new kicker kit. The chrome is pretty bad on the old one. The pulley shaft has nothing to do with that problem, its supposed to have some play, what, .005 or so, thats about right. Gotta get a manual, I promise, thats gonna happen.