Suzuki 2 Strokes

Hello guys,

So long story short, bought a bike in pieces, even the motor.
Put it all together, da da da, everything works freely, moves freely.
Today I wanted to put the clutch cover on and guess what, it doesn’t fit, seems like the kick starter shaft is sticking out a bit too much, and the gear sticks far enough out that the clutch case can’t seat.
So, million dollar question where did I go wrong ?
Assembling the kick starter shaft ? All has to come apart ?
May be I placed a bushing in the wrong orientation ?
Or a washer perhaps where it doesn’t belong, or a completely wrong washer to begin with ?

I never took this engine apart, so have been sifting through a pile of pieces to put together an engine.

I tried the cover after removing the kick start shaft outer gear and the cover fits fine.
Looking at some pics on google, I can see that my gear is sitting proud of the mating surface. Why ? I do not know.

I have pulled the top end off, motor is out.
And I am ready to split the case again, before I start moving bushings around, if someone knows what I am doing wrong, any help would be appreciated.

I have marked the shaft as it sits, and will try to see if I can get that moved back in a bit with some bushing changes. Note that I put this motor together a month or two ago, do not remember how I placed stuff.

I was still able to preload the shaft correctly, align the dot, and nothing was binding till the I made it to the clutch cover.

Exploded diagram here - https://alpha-sports.com/suzuki_parts.htm - pick year, model, kickstarter etc. It shows all parts in the correct positions.

Thanks Alan for the reply.
IIRC, I did follow the diagram when putting it together.
However I do remember that the two bushings with the locator pins could go either way.
Do you have a photo from the top showing how they are placed in the case.
I did place the washer, outside the crankcase as a thrust washer for the rachel spring against the crank case ?
Is this correct ?

Seems like the problem is sorted out.
The bushing towards the clutch case side was 180 degrees out and sitting proud, not letting the shaft retract all the way in.
Thanks all.

Good news.


Is it running yet?