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Well here I go again. New seat cover and tank is stripped and primered! Gonna talk to my buddy trek and see if we might try firing this baby up near the end of the week.
So I get timing set and finaly put some oil in her. Leave the plugs out to kick it over a few times and get things moving. Everything is turning nicely and snap. Kick start won't turn the engine over now!!!!!!! What broke?
Man I'm stumped!!! With three kids and a wife who wants her garage back I'm gonna have to think real hard about aborting this bike. Prob my loss and someone's gain. So much put into this bike. Damn
But anyway... you can drain the oil, pull the engine, then flip it upside down on the bench. Bottom engine case comes off without messing with the top end.
Kick-start shaft breaking is usually due to bad starting methods.
Either you 'slap kick' it like a 125 MX bike or your putting too much pressure at bottom of stroke (unintentionally using kick start lever like a footrest is easiest way to describe it)
The constant 'flex' eventually breaks off the inner piece and the spring pressure 'goes away'
There is also a possibility the small inner spring just broke, but I've never seen that happen
It's a pretty simple job you can easily do in a day. You will have to remove clutch to get gear-change mechanism out the way when separating cases (it's quicker than trying to finagle it)
If you need a part I have a seized 6 speed donor motor than can probably be robbed.... I think the kick mechanism is the same. If Matt or Peter can confirm. I'm in Bloomington so it is not that far from you...
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