Suzuki 2 Strokes

Friday, I was working on lining up where the kick starter lever on the gt550 should stop at when fully returned (it would spring back and hit the case) and found after clocking the shaft/lever, it no longer returns (springs up)!???
I had a student who rides/races dirt bikes tell me it's because I have the plugs out and just need compression -haven't tried that yet but..... please tell me this is no big deal and an easy fix because it has me pretty close to freaking out that I have to crack the case open to fix it....
Help....

It has nothing to do with the plugs being in or engine compression. It could be any number of things and you will probably have to remove the clutch cover to make a preliminary analysis. If it returns by hand but no spring assist, it's probably a spring that snapped.

Sadly, if the spring has broken, it is a cases apart job to fix it.

So I bit the bullet and pulled the case back apart. Better now w/ no gear oil in it and exhaust to removed ect....

Spring is fine, just not positioned properly upon first assembly.
And it was never preloaded.
Too many hands in the mix.
Long story short....

I've read the factory directions about preloading kick-start shaft 3/4turn CCW prior to placing the top case on.
HOW IN THE WORLD do you hold it (the shaft) in place until the case is on?
There are 2 bearing dowels that need to be perfect and with all that torsional tension, the shaft wants to pop out of place both while you're preloading AND especially while trying to lay the upper case down...

ARG!!!

Any help/suggestions?

Thanks!!

Hi IMQ....please forgive me if my info is not entirely relevant, as you probably know, I am a T500 man.....but I am thinking the system may be similar. On the 500, you would lay the shaft in place, and fasten it down with the small clamp that retains it in position. At the oposite end of the shaft to the kick start lever, just inside the wall of the casing, there is a tongue/tab/piece of metal which is joined to the shaft and acts as a stop against a lug in the case. That lug is actually a bolt with a plain end, which will unscrew, allowing the shaft to spin all the way round until sufficient tension is obtained at the spring.....then simply re-insert the bolt/lug.

Apologies if this is a load of useless tripe, as I really don't know if the 550 is even vaguely similar to a 500, but hopefully it is, and this info will sort your problem.

I have just re-read your thread, and it sounds like there is no clamp to hold down the shaft? Any sign of 2 small holes where it should be fitted?

Does the upper case hold it in place, and you remove the lug/stop, tension the spring, and then re-insert it once tensioned?

I have never split the cases, but this is what my Clymer manual says -- word for word

When the crankcase halves are joined, be sure that the end of the kickstarter spring is in the hole in the crankcase.

Install the ratchet wheel over the kickstarter shaft so the 2 punch marks are aligned.

After installation, turn the kickstarter shaft approximately 3/4 turn counter clockwise, then set the ratchet wheel so that it engages the stop.

I must have read that wrong.... For some reason I understood that to be done prior to installing the upper portion of the case...
I was about to JBweld the bushings into place w/ clamps on them & the shaft overnight after setting the preload....
Wow... I hope it's that easy!

Here's what I found when I took it apart:

Spring NOT in hole/detent.


How it's supposed to be!


Thanks!! I'll re-read that section and try again!!
~N