Suzuki 2 Strokes

Am assembling the GT500 motor for the T500 cafe build.
Shop manual instructions for setting the preload are a bit lame. But the Hanes manual is clear enough.

Need to remove the stopper bolt to set the preload but it doesn’t budge.
It's part # 13 on: https://www.partzilla.com/catalog/suzuk ... ck-starter

Instructions are:
1) remove stopper bolt
2) using kick start lever, rotate till the spring engages the crankcase slot
3) rotate kick start another ~ 200 degrees
4) reinstall stopper bolt

Questions:
1) any ideas on setting preload without removing stopper bolt?
2) I have an impact wrench that good for up to ~ 150 ft-lbs. But I’m leery about using it. Any concerns or suggestions?

Hey jabcb,

How did you get on with this? Seems like a tricky issue if the stopper bolt won't come out, but that spring isn't the strongest thing in the world.....

If you've completely given up on getting that bolt out then I'd probably try holding the tension using a string. First tied around the hook on the end of the spring, then wrap the string around the shaft to tension it up, then hold it by hand while I lower the kickstart shaft into the engine. Never tried it of course, but it seems to me that you might be able to hold the tension by hand (maybe with a glove)..... I've only installed the shaft in my T350 engine, so of course the T500 spring might be larger and stronger.

Best of luck!

Regards,

Jim

I used the battery-powered impact wrench that I got to fix the gray GT750 starter clutch.
Took maybe 1 ~ 2 seconds & the bolt was out.

Probably with install the kick start & bolt the cases together this weekend.

Problem solved.

Neither manual is very clear. When you use the kickstart lever to set the preload, rotation stops when the pawl hits the stop as shown in this pic.
cafe-T500-2031 by jabcb, on Flickr

You need to rotate it a little further. You can’t see the pawl & a screwdriver won’t work. I used a car drum brake tool to depress the pawl. The tool:
cafe-T500-2032 by jabcb, on Flickr