Suzuki 2 Strokes

I replaced the clutch plates in my GT550K, and as I was putting the kickstarter lever on, I noticed that the kickstarter shaft was loose, and coming out ot the case. I could push it back in, but....at no time will it turn the engine over.
Judging by the polish on the shaft where it exits the case cover, the shifter should go back another 1/8 to maybe 3/16ths of an inch. The shaft will go no farther in. I have tapped it while rotating the engine, with and without being in gear, yet it stops solidly, short of where I think it should be. any ideas as to what is wrong, and the possible fix ?

Does it spring back when you push the kick starter down?

Thanks,,,,Yes, unless it is pushed in, the shaft will come out if the kickstart lever is movedn. When pushed in, the shaft comes to a solid stop.

Did the kick start work BEFORE you pulled off the clutch cover?
Remove the cover again and check that the ear on #2 in the diagram below is sitting against the top of guide #6.

The kick starter worked fine, even as I pulled the cover off. After removing and replacing the entire clutch ass'y. the kickstarter did not engage.

Not sure about the fix you mention, as it appears that the engine case would have to be split in order to even see the parts 2 and 6.

You can see #2 and #6 after you remove the clutch cover!! No need to split the cases! Check to see that the ear or pawl on #2 is sitting on top of #6 and not down between the two bolts.

I will give that a try tomorrow and file a report. Thanks.

Checked out the " fix " today...The tang on Part # 6 was correctly installed on Part #2. I removed Parts 6 & 7, still no connection to the engine. The boss holding Parts 6 & 7 is integral with the top of the crankcase, and keeps the kickstarter shaft, Part # 1 from being withdrawn. Nothing is visible internally, as Part # 9 obstructs vision into the crankcase/transmission case.

Problem solved. a thrust washer, part 16, was missing. discovered it today, and it will solve the problem of the kickstart shaft moving horizontally. Thanks for the help, Cliff, it made me double check the pieces.

That's the thick one that sticks to the case when you remove it!! I remember that washer now!! Let us know if everything works now!