Suzuki 2 Strokes

could you please look at my photo and advise me if these two positions are correct before i start my rebuild and put the cases back together? The kick starter 'lever' or arm is at 3 0 clock and it is IN FRONT of the shiny steel arm which is secured to the side of the gearbox lower half case.
The gear selector - although you can't see it so well - or rather should i say 'foot change shaft' teeth have engaged with the gear selector with the first tooth of the FCS being on top of the first tooth of the GS.
Is that the default position?

i know. I know. I should have photographed the side view before messing with them.

Any help appreciated.

MJ in Beirut

Hi!
The spring at the selektor shaft seems to be in wrong position, the ends must not be crossed.

Assemble the crankcase without kickstarter spring tension. Then tighten the spring by using the kick starter lever fitted at the shaft and insert the tab behind the guide Markus

appreciated and understood first part about spring on the gear selector - but not entirely sure about the kickstarter. Do you mean that the default position of it - before putting the cases back together - should be like this? With the small arm tucked behind ?
thanks Markus!


MJ

i'm still a bit unsure, Markus. Are you saying that remove the arm and make sure there is no tension in the main spring (not even twisted so that the tiny arm of the spring hooks into its hole - BEFORE putting the case back? And then once the case is on, twist the shaft anti clockwise until you have a load of tension, then hold it, and slip on the arm and tuck it behind the second arm which is on the side of the case?

thanks

Hi!
Do you have the GT380 Parts Katalog?
If not, download here: http://www.suzuki-gt.co.uk/images/Refer ... 0KLMAB.pdf

I call parts as
# kickstarter spring: the larger, stronger spring in the inner Gearbox, not to be seen when the Gearbox is assembled. Katalog Fig. 20, Part 15
# small spring: Fig. 20, Part 3, located behind
# "starter, kick" (so called in Katalog) Fig. 20, Part 2. With the "nose", or tooth, or hook or whatever
# guide: Fig. 20 Part 5
# Kickstarter gearwheel: Part 9

When assembling the gearbox, both springs are relaxed first.
Then the kickstarter spring is tensioned, using the Kickstarter-Lever (Part 19).
Turn it anti clockwise until "starter, kick" can be pushed all the way inside (against the small spring).
Then turn the Kickstarter-lever back, so the "nose" of the "starter, kick" will slip behind the guide.

Later, when you'll start the engine using the kickstarter lever, the "nose" will slip out of the guide and the "starter, kick" will be pushed against the Kickstarter gearwheel by the small spring. Then the teeth at the sides of these two parts engage in one another, the force will be transferred and the engine started.

You should try to change through the gears, while the transmission is still open, to see if everything is OK. This may take a few extra helping hands to hold the shafts in position.

good luck
Markus

HI Markus
thanks for that advice, especially about the gears. I will check them soon before i m about to put the cases back.
But i have just one question.

When you pull down the kick starter lever (presumably about 90 degrees anti clockwise) at which position is the starter kick at, when you slide it on?

My point is does the end of the start kick travel from left to right and end up at the end of guide OR does it go there in that position straight away (while you hold the kick starter at 9 o'clock)?

Do you see my point?

best

mj in beirut

good morning...

Ramjam wrote:...When you pull down the kick starter lever (presumably about 90 degrees anti clockwise) at which position is the starter kick at, when you slide it on?

This depends on how you put the parts together. The kickstarter lever can be mounted in any desired, even unreasonable, position. The "starter, kick" can be placed on the kickstarter shaft in different positions, so that the "Nose" points to 12 or 6 or 9 o'clock or any, determined by the spline ((?)Teeth) of the kickstarter shaft. You have to choose the right position.
It must be all assembled so, that (after the engine is completly fitted), when you let go of the kickstarter-lever, it is moved reliable into the rest position by the kickstarter-spring-tension. While the kickstarter-spring turns the shaft+lever back, the "nose" of "starter kick" will be catched by the guide. "nose"+guide are the end stop for the rest position.

If not, pull of the "starter kick" to free it from spline, turn it one step/tooth, push it back onto the shaft and check its function again. If the kickstarter spring tension is too small in the rest position of the shaft/lever, turn the "starter kick" on the shaft by one step clockwise. If the tension is to large, turn it anti-clockwise. (If the kickstarter spring tension is too large in the rest position, you will notice you cannot push down the lever completely, because the spring reaches its end stop)

My point is does the end of the start kick travel from left to right and end up at the end of guide OR does it go there in that position straight away (while you hold the kick starter at 9 o'clock)?

uh...What

Do you see my point?

not really ... sorry, probably it's my english...
Markus