Suzuki 2 Strokes

Even though I have the service manual I am having a time with installing the kick start mechanism. When I get the parts to where I think they should be the spring has such a tension that it pulls both end partially off of their dowel pins even with the holder plate firmly screwed down on shaft. Any clues or hints appreciated. ///Pat

I have a TC250 but I would think they may be similar. Had the same issue as you til I learned the trick on mine. The case halves had to be together, then I removed the big clip on the kick start side. After that, it would slide slightly inward until it cleared the "stopper" on the other side. Put the kicker on and cranked it about 150 degrees until it was on the other side of the stopper, slid it back into place and put the clip back on. Voila! Tension is there and it's locked in place where it needs to be.
Someone should be along to correct me if I'm wrong. What bike are you working on? Good luck, Doug

Thanks Doug. Its a 69 T500. It may be that the kick start shaft is going to be raised slightly until I put the top half of the engine back on. Will play around with it later today to see if I can improve it some.

Ok I think I have it installed correctly. The end with the small bearing (close to the spring) is pulled up just slightly up on its dowel pin but when I put the engine case on it will pull down. I turned the shaft about three fourths of a turn in order to get the stopper arm under the stopper bolt. So I guess the spring is supposed to be under pretty heavy tension even before the kickstarter is engaged. I do recall when disassembling that when I removed the stopper bolt it kind of startled me when the tension was released.

Kicker springs are under heavy tension all of the time.


Lane

I'm glad someone put this up. I'm having the same problem with my T350. Pulling the clip and rotating the shaft should solve my problem without splitting the cases again. Thanks.