Can't tension kickstart shaft

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ISR64
On the street
Posts: 27
Joined: Fri Sep 07, 2012 1:33 am
Country: uk
Suzuki 2-Strokes: t500

Can't tension kickstart shaft

Post by ISR64 »

Hi All,
Had my 1972 T500 engine in bits for rebore and new seals. Made an oil dam as advised and now refitting kick start shaft. Manual says attach screw holder down, engage spring in case and then turn 200 degrees clockwise... cant do that as I turn shaft with kickstart shaft pawl locks against bearing tab... can turn by pushing pawl in with screw driver, is this right though??
Thanks.
titan performance
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Posts: 1306
Joined: Wed Oct 13, 2010 2:55 pm
Country: England
Suzuki 2-Strokes: TS100, T200, GT250, T500, GT500, GT550, GT750, GS750
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Re: Can't tension kickstart shaft

Post by titan performance »

Have you removed the stop? There's a bolt through the case that limits the shaft travel, the head of which is in the clutch compartment. Just inside the case, between the clutch compartment and gear box, there is an arm on the kick starter shaft......slowly turn the shaft and you will see it meet with a stop. With this removed, the kick start shaft is free to turn 360. I think loading the return spring would be anti clockwise wouldn't it? Anyway....once you have the required tension, simply replace the stop bolt.
Keeping old 2 strokes alive !
ISR64
On the street
Posts: 27
Joined: Fri Sep 07, 2012 1:33 am
Country: uk
Suzuki 2-Strokes: t500

Re: Can't tension kickstart shaft

Post by ISR64 »

Yes knew about that thanks. Eventually found the pawl has to be pushed back to turn the shaft, the Haynes manual is not complete in its description.
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