bw200 kick starter fell out - WTF?

[rally4x4racer]

hey guys, I have no been on here in forever and DANG - the site is totally different. Anyway, was working on the wifes BW earlier and somehow pulled the kicker shaft out.. after a little :wondering and :confused: I knew that someone on here would be able to help me put it back together!! So here I am..

I am looking at the service manual and it says "make sure there is room for the clip to go home" but it does not say what home is.. so... here I am wondering what the spring clips to... is it that rod? see label A.. Also, what about this clip thing? does it just seat into the case? (see where I am pointing) - I drew lines where the shaft goes into the case... also I have a graphic from bike bandit that I was using... the peices look like 2 and 5.

thanks in advance!!155255155256

[kb0nly]

The spring hooks on that post as you have it marked, that much i know your right on. I havent seen inside one of those in forever... I am pretty sure the tang of the spring goes in the slot below the hole, but you could be right and it goes to the side as well, see which one it lines up with and fits into if nothing else.

You must have been gone a while, i don't remember when they last changed the look of this site!

[rally4x4racer]

only a few years.. got busy with school and work and stuff.. I remember the site having a monster green effect of somesort... Plus, it was way harder to put pix in a post, i was using photobucket to maintain.. Also, that kicka$$ track banner was not at the top of the page. Anyway... its almost winter in FL so i intend on playing with some bikes...

Do you know if that shaft (#1) goes in positioned like the diagram shows it? I was totally not ready for it to come out so I was not paying attention at all..

[rally4x4racer]

thanks, I see the slot you are talking about now.. i will try that.

[Vealmonkey]

LOL! What a classic comeback thread. Put a little fire to it, it should melt right together! LOL Jef, only you buddy, only you.

[kb0nly]

I believe you are correct on the shaft placement... I was looking through some old pictures i had of inside one but it was the opposite side.. Dangit.

[rally4x4racer]

shut it pat.. mt wants her bike running.. get off your ass and send me some shots of the inside clutch cover.. last thing i wanna do is screw it up and have her riding mine!! fire fixes everything.. this ones not ready for the pit yet, i only burn 'em down after i spend lots of money on 'em

[Vealmonkey]

What year are you working on, they are slightly different between kick only and electric start. I really don't feel like taking mine apart and having my shaft fall out! LOL I really need to swap out my front end for the modded stock triples to take the tri z fork tubes. That way I can finally get my nos headlight cover and nos front fender on an maybe the rake on the front end not look so wonkie.

[rally4x4racer]

its the kick only.. i might go roll around in the garage floor and see if i can get it kickin..

just put a new air box set up on the kids z50... didn't help as much as I thought it would. Stupid thing has real trouble idling and initial throttle.. like the pilot jet is not big enough. they have been riding it and the bw80 a lot.. ... they trash that 50 bc it is not running right, tho.

btw - looks like my last post was circa 2008

[Vealmonkey]

I was just looking at the exploded drawing again and you do realize your clip is #6 right? So when installing all the other parts, there may be a spacing washer, but the manual is saying that you have to have enough room after you put the clip on to be able to put the rest of your parts on the shaft. If not, you've done something wrong, a part out of order or something along those lines. You must have busted your external snap ring. And what you have to be aware of, the snap ring honda uses may be of a special thickness and not just a generic, run of the mill metric snap ring. That's what makes putting these things together a real mess sometimes and more often than not, a previous owner may have installed a generic part from the local hardware store and it may not be quite right. You'll get it I hope without burning it up. I hope you do better with this than the, was it the bmw or the mercedes? LOL OR maybe it was both!!!!

[rally4x4racer]

155391

Thanks VM.. I went out there and laid in the garage floor for a few minutes about 3AM this morning. I must have been high when I posted this because I looked at it for a few minutes and realized how it worked. I went ahead and colored the picture to make sense of it in case I am wrong. I still have to grind down the swingarm nut to make the case fit, so there is a little time if someone needs to jump in and save me. This is how I have it:

1) position the loopy looking pin just past the large end of the weight
2) slip the shaft in place, set the pin in its track, and twist the shaft forward so that the large end of the weight (A) on the shaft rests on the stop plate (A) of the case
3) pull the spring down and hook it around the catch


As always thanks for your help guys... now if someone can tell me how to change my signature I would!!

also, any cheap ideas for the z50 carb/air issue? I dont have the cash to make it a money pit, plus the boys have fun trashing it still - would like to make an easy swap on the carb - ATC70?? I think this carb is beyond function

[Vealmonkey]

You shouldn't have to grind anything to make it fit. If you are grinding, there is a problem. You have the manual, so obviously you have a problem following directions and when all fails, force it to fit. I don't think anyone on here needs to give you any pointers, just hammer and grind away.

[rally4x4racer]

the grinding was to fix the previous owner's attempt to remove the swingarm bolt with what appears to be a screwdriver? the flat edges of the nut are boogered up and the nut is turned so that one of the hex corners - in all its boogered up glory gouge the case when pulling/installing. Don't worry, i just used a file to bring it back.