Elite Kickstart Assembly, anybody have any detailed pictures

[Chicago Ben]

Guys- for the life of me I cannot get my kickstart assembly together.

It's almost like the spindle and gear/starter idle don't even work together. I can install the spring and spindle but I can't install the gear at the same time? I can do one or the other...does anybody have any detailed pictures or process tips on how to put this thing together? the shop manual doesn't do much justice


key:
12: spring /kick return
11: bush/kick spindle
10: spindle
9: gear/starter idle

[Chicago Ben]

anybody

[KingJeff801]

I recall the kickstart(the part your foot kicks) has to be down all the way like you just kicked it and the gear should slide into place and when you let go of the kick start it springs back to where it should, the part on the gear that has the guide(#8) should be almost all the way out, not sure if this is what your looking for , it took me a good 10 frustrating minutes to figure out.

[Chicago Ben]

I recall the kickstart(the part your foot kicks) has to be down all the way like you just kicked it and the gear should slide into place and when you let go of the kick start it springs back to where it should, the part on the gear that has the guide(#8) should be almost all the way out, not sure if this is what your looking for , it took me a good 10 frustrating minutes to figure out.

so when its all said and done does #8 sit all the way at the top of that post?

[evilone]

#8 slides over the post and bigger open end of #8 clips on #9 in the groove. Keeping #12 in place before #10 is all the way in is a PITA. I had pics at one time, i can get another pic tomorrow if you don't get it figured out.

[KingJeff801]

#8 sits about a 1/4" from the top if memory serves, if you cant get it today let me know and I will take some pics tomorrow and post them for you.

[ALOW1]

Did you figure this out Ben?

[Chicago Ben]

I haven't had a chance to try to install the kick assembly again since I posted the question. I think I'll try after dinner here but Eliteguy50 (thank you by the way) sent me an e-mail with pictures and his description off his af05 crank. i re-sized them so everyone can see here. I'm just glad my half moon gear isn't odd, you guys can see that the first few teeth on this gear are actually welded together. I thought I had a gear that had been messed with.


"The first 3 are of the kickstart in the natural position. the 4th is the kickstart without that kickout gear installed that turns the crank shaft over, notice how it rotates more, so that kickout gear stops the half moon from resting on the case from spring tension. The last picture is full rotation of the half moon gear, notice that I am holding the kick lever almost all the way "straight down" (as if it were installed) with my belly

'natural position':


'natural position':


'natural position':


'kickstart without that kickout gear installed that turns the crank shaft over, notice how it rotates more, so that kickout gear stops the half moon from resting on the case from spring tension.':


'full rotation of the half moon gear, notice that I am holding the kick lever almost all the way "straight down" (as if it were installed) with my belly':

[Smooooth]

Looks just like what I got working on my 86 Spree yesterday. My problem was that the mating surfaces of the 2 gears had some surface rust on them and with that increased friction, was binding up the entire operation. I cleaned all of the mating surfaces, applied a very liberal amount of grease, re-assembled, and now it works like a champ. Once I figured out that the whole assembly process went together much easier with the kick start lever attached, it was together in less that a minute.

Stephen

[ALOW1]

Looks just like what I got working on my 86 Spree yesterday. My problem was that the mating surfaces of the 2 gears had some surface rust on them and with that increased friction, was binding up the entire operation. I cleaned all of the mating surfaces, applied a very liberal amount of grease, re-assembled, and now it works like a champ. Once I figured out that the whole assembly process went together much easier with the kick start lever attached, it was together in less that a minute.

Stephen

I agree. Ben, You should scrub the inside of that housing and get her nice and clean. Add a small amount of grease or oil and then it should move much easier. I know you would not think it would matter much but after I cleaned all of the ones I have owned it seemed like each one worked smoother.

Eliteguy50 (thank you by the way) sent me an e-mail with pictures and his description off his af05 crank.

Eliteguy50 is a good guy. I have met him and rode with him before, he seem's to know his stuff pretty well too.

[Chicago Ben]

I agree. Ben, You should scrub the inside of that housing and get her nice and clean. Add a small amount of grease or oil and then it should move much easier. I know you would not think it would matter much but after I cleaned all of the ones I have owned it seemed like each one worked smoother.

Those are the resized pictures of Eliteguy's crank housings, not mine. Mine have been scrubbed with a toooof brush.

[eliteguy50]

Those are from my parts pile so no need to clean them. If you are cleaning them, use grease, not oil. The oil will work in the short run but it will dry up fast collecting all that belt dust and just hold gunk in those teeth.

[Chicago Ben]

wow!!!!!!!!!!!!!!!!!!!!!!!

hey guys, checking back in here to let you know I figured this out.

My solution: USE THE CORRECT PARTS!!!!

somehow I mixed up my elite starter gear with my old 85 spree starter gear


moral of the story: LABEL YOUR PARTS!!!!

[Trafficjamz]

wow!!!!!!!!!!!!!!!!!!!!!!!

hey guys, checking back in here to let you know I figured this out.

My solution: USE THE CORRECT PARTS!!!!

somehow I mixed up my elite starter gear with my old 85 spree starter gear


moral of the story: LABEL YOUR PARTS!!!!

Ha.........I did the same thing a while back Yeah you can not put the spree parts in there, and expect it to work.

[MrChimpo]

My half moon gear has a weld or something on the 2nd tooth (from the start of the worm gear) so that when the kickstart is pulled back to its resting position by the spring the stop on the case where the half moon gear hits is actually 1/2in from resting. Is the half moon gear supposed to have a weld in it somewhere or clean teeth all the way through?