1974 GT550 kick starter preload

[vdavidoff]

I'm trying to put my 550 back together (replaced crank seals/bearings) and there's just something I'm not understanding about preloading the kick starter. I have read everything I can find here and in the shop manual and I just don't get it. I mean, I think I see how if the mechanism was preloaded, the ratchet would be held with clock-wise tension against the stopper plate, but I can't figure out how to actually do the preload. It seems it's not possible with the case split, and with the case together I don't see how it could be done without removing the stopper plate or the circlip that holds the ratchet on, which the manual says nothing about. I didn't take the assembly apart, so the punch marks on the shaft and ratchet should be aligned already.

Can someone please explain it me, perhaps with pictures?

Thanks.
Andy

[titan performance]

Hi Vdav....
This one cropped up real recently.
Hopefully this link will help you out.
viewtopic.php?f=2&t=6155" onclick="window.open(this.href);return false;

[vdavidoff]

Well, I think I figured it out. Here's what I did:

1. Put the case together
2. Pulled the circlip that holds the washer and spring in place on the outside of the ratchet wheel
3. Confirmed the punch marks on the ratchet wheel and the kick starter shaft were aligned
4. With the circlip, washer, and spring off, slid the ratchet wheel off the shaft far enough that it could spin past the stopping block
4. Used the kick start lever to rotate the shaft CCW ~3/4 turn then slid the ratchet back on (punch marks still aligned) so that it rested on the stop.

This works fine, kind of. The spring is definitely preloaded and the kick starter feels normal. Except for when I torque down the case bolts at the back of the engine on the top. Even just barely snugging them up causes the kick starter to fail to return after being pushed down. I discovered this after torquing all the bolts down (per the specs in the shop manual) when reassembling the case.

I guess something in there is pinched but I don't know what it would be. Everything looked aligned and fine when I put the top on. Spring in the little detent, cam things aligned with their little hole and dowl doohickies, etc. I'm growing weary of splitting the case, cleaning up the old case sealant, trying again, etc.

Andy

[Cliff]

This might be a bit after the fact, but I always dry fit the cases together (no sealant) first just to make sure that everything is in place and doing what it's supposed to do. Once I'm sure of the assembly, then I split the cases, apply the sealant and reassemble the unit.
As for the kickstart problem, something is binding when the bolts are tightened. Something is not right, find out what it is and correct it!

[carson shmarson]

I have mine apart right now and it spins freely. It was stiff at first but now I get spring tension but the shaft will move out and release all my spring tension. I fear I have to pull the engine and split the case or can this all be done from outside the engine without opening it back up and cleaning the gasket maker off.and starting over

[carson shmarson]

I did split the case again the spring came out of its notch, the case got torqued down on a pin which killed it. After I made another one a reassembled everything and all good. And you do put the case together and then pull that stuff off of the kick starter shaft, and then do the tension and put it all back together then you are good to go. Thanks for the info too guys