Suzuki 2 Strokes

Excellent news that a member here helped you sort this!!

You should post a pic of that washer to include dimensions of outer and inner diameter. As mentioned, it may go in the clutch assembly. Might be best to ID it before running the bike.

Ramjam wrote: UPDATE
Sportson was bang on with his hunch. In fact i HAD placed incorrectly a washer on the outside of the cog. Soon as i whiped it off, kiskstarter works well. Problem now is where did it come from ??? Oh bugger.

Glad you found the problem. Could the washer be from other end of the kickstart shaft? (part 17 in the exploded diagram)
I can sympathise with your "Oh bugger!" moment. I made a similar error on my bike with the stepped washer on the clutch shaft. Didn't notice I had omitted it until after I had bolted and sealed the two crankcase halves together. I think I said more than "Oh bugger" at the time.

Ramjam wrote:

Ramjam wrote:

sportston wrote:Then can we assume from your line of questioning that you have inserted an unnecessary washer between the kickstart cog and the clutch cover?
If so, ditch the spare washer and you should have a kickstart that works. It would raise another question though. Where did the spare washer come from? Was it supposed to go somewhere else?

Exactly. But maybe my mind's playing tricks on me. For sure, that washer was there before at some point. But just last weekend i had the case off and i didn't recall seeing it. Will have it off soon and settle my curiosity. but yes, if it's there, where did it come from? Behind the clutch assembly? Or one of the other cogs?
Yikes

UPDATE
Sportson was bang on with his hunch. In fact i HAD placed incorrectly a washer on the outside of the cog. Soon as i whiped it off, kiskstarter works well. Problem now is where did it come from ??? Oh bugger.

If someone could post a picture of the entire clutch assembly, i would be very grateful. cheers

Like this?

sportston wrote:Like this?

Brilliant. thanks so much. Im pretty sure, looking at this pic, that i have only replaced one of the two washers, which i can now see in the diagam. Cheers for that.

You're welcome. You can usually get parts assembly pics like this from Partzilla or in this case Robinson's Foundry. I have found them to be invaluable in my own rebuilds

sportston wrote:You're welcome. You can usually get parts assembly pics like this from Partzilla or in this case Robinson's Foundry. I have found them to be invaluable in my own rebuilds

Yep and for the 'big picture'.....you gotta love that exploded engine artwork......























and for those peeling an unfamiliar engine apart, a service manual and a camera can be their best friends.