Suzuki TS50 kick-start mechanism refitting problem. HELP PLZ

[jkam]

LO all, Suzuki TS50 kick-start mechanism refitting problem in that it's not turning the engine - not engaging. Weather as prevented further investigation though I made a few unsuccessful attempts before dusk intervened. I looked at a manual but no diagram or info. Any help gratefully appreciated.[img][/img]
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rock not rap

[Vincent]

Any chance you can post a pic of under the side cover? I take it it's the mechanism you've replaced and not just the kicker itself?
what year's the bike?
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Space Is Deep

[jkam]

Hi,
Thanks
Yep, I replaced mechanism underneath.
1985
Photo
I hope that is the way to add a piccy as I struggled & that's all I could achieve.
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rock not rap

[Vincent]

[Vincent]

Does this help at all:-

www.cmsnl.com/suzuki-ts50-1994-xkr_model14162/partslist/FIG12.html#results
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Space Is Deep

[jkam]

Thanks for your help & apologies for the delay.
I have a PB account but having tried listing editing options I can't manage either nor do I understand PB links even though I uploaded a photo..

[img]https://i30.photobucket.com/albums/c330/axzed/23613016Large_zpsebe96ed4.jpg[/img]
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rock not rap

[Vincent]

First impression looks like the two gears aren't meshing correctly. Spacer missing from the inside end of the kickstart shaft maybe?
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Space Is Deep

[Vincent]

[DMCpro]

Hi there your missing parts there's a small price of metal tubing like a collet that goes behind the lower (kick start) cog. Take a look round the garage. Also did you replace with a new part? Have you put the parts side by side to check they are identical?
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Honda CB-1, TS125X
VW Golf Estate

[Vincent]

I don't know that it'll help, but I can see how it works now, (I wish everyone that posts a problem on here could post a photo, it makes it much easier), as the kickstart shaft turns, the gear moves outwards, as it's on a "worm" on the shaft, and engages with the other gear connected to the primary drive. It could just be that the shaft isn't located correctly.
I think that the end of the retaining spring, (No.7 in the blow up), isn't located right either. It might fit on the part of the casing that juts out, a few degrees to the right as you look at it.
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[jkam]

I can refit so that it is further back & meshes but it started raining that day & I just bunged it in quickly.
When I fitted it it didn't engage when cranked and no return even though I fitted the spring with tension.
The PB gear icon tip really helps....ta.
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rock not rap

[jkam]

Thanx again for the responses. Posts seem to have lost sequence & my photo has been removed (why?). Did someone annotate parts for clarity?

I went out (no garage) and had another attempt at refitting and I have succeeded. I was in a rush previously as it was near dusk & spitting rain. With better light and time I noticed the fairly obvious as regards positioning it all correctly. However, the kick lever is not returning. I felt spring tension before I replaced the cover but having forgotten to lubricate the seal I think that may be the problem. If not I hope I can tighten the spring a full turn. Thanks again for all your help and time.
Chrz All
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rock not rap

[Vincent]

I can still see yr pic.

Glad you got it sorted, they can be a bit awkward. did you move the no.7 spring? I may be wrong, but here it is in the pic, it looks like it may foul the gear change.
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Space Is Deep

[jkam]

Weird, I get a blank box with .....("This person moved or deleted this image" photobucket) Yes, I put it at 5 o'clock. As I said, I just stuffed it back in a rush - as in that photo. I hope I am right about the none return. ATB
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rock not rap