The world's worst kickstart design

[Gazdaman]

So for ages I've had loads of problems kick starting my te 410, it's been kicking back incredibly hard. And eventually today it killed the kickstart mech.

Whether my poor kick start technique caused the kick backs which killed the mech, or whether the mech was damaged in the first place which caused the kick backs which killed the mech. I don't know.

But yesterday I felt the kickstart slip slightly, and today I felt the return spring stop working. So I popped the clutch-side side cover off after draining the oil and found..

https://www.gaz-racing.co.uk/images/vehicle_1311.JPG

As you can see, that plate at the bottom of the photo holds that little cam on a spring pushed in, until it gets past the end of the plate, when it springs out and locks into a notch on the inside of the kickstart idler gear.

That plate is also bent at 90degrees at the end, which holds the kickstart return spring, that's completely sheared off.

https://www.gaz-racing.co.uk/images/vehicle_1312.JPG

Which you can see is also quite worn on the notches.

How the hell does it expect a little semi circle pushing into another little semi-circle with a small spring to have enough purchase to kick over an engine like this.

(Especially when you add a ham-fisted twat like me).

And now I've found that getting new parts for a Husqvarna is nigh on impossible. I've contacted a couple of dealers and I'm waiting for some quotes now, but I'm almost expecting it to be as cheap/cheaper to buy a second hand engine.

From the parts I've found on eBay, I've found the idler cog for about £30 and the plate for about £20. Hopefully new parts will be a similar price.

What the hell is wrong with a pawl cog design! That works and won't strip when you give it some welly!

Also, the kick start shaft is bent, so I'm thinking that may have been why the kick start wasn't disengaging, and therefore kicking back.

Gaz

[powermandan]

lol, i knew from the post subject that this was going to be a husky.


try husky sports, near southampton. havent actually bought anything from them yet, but the prices ive been quoted for the stuff ive enquired about has seemed very reasonable.

Mine kicks back quite hard if you dont complete the entire kick, usually cuz your tired from the previous kicks. so it might just be a qwerk of the mechanism.

i dunno if this is teaching you to suck eggs, but i didt know before i was told recently, get it to TDC and then take it a little bit past with the decomp lever before kicking, makes it a bit easier
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TE610

[Gazdaman]

I actually solved this problem today!

The reason it was kicking back so hard was the magnets on the flywheel had slipped, meaning the timing was out by 25 degrees.

I got the magnets realigned, new kickstart mechanism, new stator plate (the last person had butchered the hell out of the it to try and get the timing right again)

And it fired up just fine, I can even kickstart it with my left foot.

Happy days!

Gaz

[yen_powell]

All I'm saying is..... Jawa combined gear lever/kickstart.

I have to go and lie down in a darkened room now.
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