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falloutboy
03-31-2013, 06:12 PM
On my 86 Tecate, I am having trouble with the kick starter return spring. It is hooked in the correct hole but with the clutch cover on, it acts like the return spring in not there. I have to manually pull the kick start lever back up. I checked the shaft and the hole in the case and didn't feel any thing that felt like it would cause a hang up. I have a couple other kick start gear assemblies so I put one through the case and it felt fine. I'm going to try one of the other return springs and see what that does. If you have any suggestions or insight, please, feel free to share.

Thanks.
hondawasaki
03-31-2013, 06:23 PM
Did you counter wind the spring? or just install the spring in the hole? The spring needs wound tension on it, if your doing that I'd take it back apart and double check that everything is in there, and in there the right way.
falloutboy
04-01-2013, 04:50 AM
The first time I put it together I had to wind the spring about 180°, basically from the top to the bottom where the hole is. It's apart right now. I'm hoping I can get time to get it back together this week.
broncobeast32
04-01-2013, 05:22 AM
I had the same issue, make sure it is wound all the way and that the little white bushing is in correctly.
christph
04-02-2013, 07:42 AM
It has been a while since I've had mine apart but yes the spring needs to be under tension when you install it. One end of the spring goes through the hole in the spindle and the other goes in a hole in the case. It can be challenging to install.
falloutboy
04-03-2013, 01:33 AM
K. It sounds like I'm doing it right. Hopefully it works out
falloutboy
04-04-2013, 01:51 AM
I think I may have got this figured out. I changed out the return spring and borrowed a thrust washer from another kick start assembly for the end of the shaft, so now instead of 1 thrust washer between the kick start shaft and clutch cover there are 2.

I think a good portion of my problem was the kick start shaft was deflecting ever so slightly because of too much end play. It feels much better now. I guess time will tell.
falloutboy
08-13-2013, 10:53 PM
just checking back, and that seemed to be the trick. I haven't had an issue with it all summer.