Kick started hanging up

[cant-drive-55]

'59 w/ aftermarket transmission. Replaced start gears last year. Hard to grind gear off shaft. Now motor wants to while pedal is still at the bottom of stroke. Guessing cam logs may not be fully depressing start gear. Not sure what changed over the winter.

Anything else I can try?

[RooDog]

Yes, you can try going back and correcting your posting so that we can understand what your problem is.

Also a picture of the inside of your kicker cover, and the starter gears would be helpful. It sounds like to me that the kicker's gear has come loose on the kicker arms shaft.
....RooDog....

[Buddhahoodvatoloco]

Man be nice

Yes, you can g try going back and correcting your posting so that we can understand what your problem is.

Also a picture of the inside of your kicker cover, and the starter gears would be helpful. It sounds like to me that the kicker's gear has come loose on the kicker arms shaft.
....RooDog....

[cant-drive-55]

Late night post with autocorrect doesn't help.

- The old starter clutch was locked on shaft, requiring a grinder.
- Engine tries to start, but clutch grabs and stops engine with a loud sound. I guess is the starter gear cams are not completely displacing the starter gear against the click spring.

Thanks for your input. I'll get it figured out.

[nmaineron]

Some of the old aftermarket kicker gears were just junk. They didn't cut enough teeth on the gear at the end of the stroke resulting in what you are experiencing.

[cant-drive-55]

It seems like the mainshaft is not sized correctly. If I tighten the clutch gear on the shaft so the nut is flush with the shaft (very loose), I cannot push the kicker gear against the spring enough to get a 1/8" gap between the gears.

Perhaps the shaft diameter or taper is incorrect. I'll have to compare with another

[cant-drive-55]

Replaced the starter gear and clutch gear on the shaft. I see the kick gear needs to travel completely to the bottom to disconnect the starter gear. Any less and the kick gear/starter gear bind the engine that's just beginning to start. I find it difficult to get the kick pedal down to this point.

Are there differences between the original kick gear and the available import ones? I'm curious if there was any gear with disconnect tabs closer together.

[nifty]

Check your spring, many need re-working
Spring maxim: The 33391-36 conical spring must compress/telescope completely flat. With all Starter Clutch parts installed to mainshaft, the Starter Gear must be able to freely slide on mainshaft and fully compress spring, so that ratchet teeth tips of starter gear have a separation gap of 0.100”- 0.125” to corresponding ratchet teeth tips of Starter Clutch. At which point the back of SG must touch mainshft nut.
If above not achieved, do not attempt to assemble rest of kicker

Check first with parts off bike, spring on gear, gently push gear & spring against a flat surface, gear should touch surface, spring should go completely flat with no catching or binding

Spring ends can be carefully shortened & smoothed so they don't overlap/bind

Also some repop mainshafts have projecting thread after nut & tabwasher torqued against bearing, easiest fix is machine a little off inside edge of starter bush until starter gear kisses raised part of factory nut, of course you must also run the correct factory nut

Nifty

[1950Panhead]

September 3, 2019
I have fallen and cannot get up.