Post by LesS on Mar 26, 2010 12:44:39 GMT -5
Here are simplified instructions on how to reinstall the XS650 kickstarter.
Re-installing XS650 kickstarter
1. Put the top spring on.
Partially insert the kickstarter assembly until the return spring can be slipped over its anchor point. In other words, put the top spring anchor on, but do not push the assembly in far enough to engage the gears.
2. Place the U shaped spring clip (which is on the bottom at about 5:00 o’clock) in the groove and push it back all the way into the groove.
In other words, position the kick clip in the groove - align and bottom the U shaped spring clip in the groove.
3. Put the kickstart lever on the splined shaft temporarily and rotate the kick axle counterclockwise about ½ to ¾ turn.
4. Push the shaft in so that the gears mesh/engage.
5. Check to make sure that the kickstarter works properly.
With the key “off”, kick it over slowly using your foot on the kickstart lever. The kickstart lever should return by itself (due to the spring return action).
6. Carefully remove the kickstart lever from the splined shaft so that you can install the right hand crankcase (clutch) cover.
Make sure that the kickstart shaft assembly is held in place and does not become disengaged.
7. Put on the right hand crankcase (clutch) cover using just 2 screws for now. Make sure to carefully hold the kickstart shaft assembly in place so it does not become disengaged. At this point only put in one lower bolt and one upper bolt – make them snug, but not fully tightened
8. Now, put the kickstart lever on the splined shaft and check again to make sure that the kickstart works properly.
Attach the bolt that holds on the kickstart lever. With the key “off”, kick it over slowly using your foot on the kickstart lever. The kickstart lever should return by itself (due to the spring return action).
This step is done with only two bolts holding the right hand crankcase (clutch) cover in place.
9. If kickstart still works properly, put in the remaining bolts for the right hand crankcase (clutch) cover. Re-check the bolt that holds the kickstart lever on for tightness (torque spec is 11 to 18 ft-lbs).
Re-installing XS650 kickstarter
1. Put the top spring on.
Partially insert the kickstarter assembly until the return spring can be slipped over its anchor point. In other words, put the top spring anchor on, but do not push the assembly in far enough to engage the gears.
2. Place the U shaped spring clip (which is on the bottom at about 5:00 o’clock) in the groove and push it back all the way into the groove.
In other words, position the kick clip in the groove - align and bottom the U shaped spring clip in the groove.
3. Put the kickstart lever on the splined shaft temporarily and rotate the kick axle counterclockwise about ½ to ¾ turn.
4. Push the shaft in so that the gears mesh/engage.
5. Check to make sure that the kickstarter works properly.
With the key “off”, kick it over slowly using your foot on the kickstart lever. The kickstart lever should return by itself (due to the spring return action).
6. Carefully remove the kickstart lever from the splined shaft so that you can install the right hand crankcase (clutch) cover.
Make sure that the kickstart shaft assembly is held in place and does not become disengaged.
7. Put on the right hand crankcase (clutch) cover using just 2 screws for now. Make sure to carefully hold the kickstart shaft assembly in place so it does not become disengaged. At this point only put in one lower bolt and one upper bolt – make them snug, but not fully tightened
8. Now, put the kickstart lever on the splined shaft and check again to make sure that the kickstart works properly.
Attach the bolt that holds on the kickstart lever. With the key “off”, kick it over slowly using your foot on the kickstart lever. The kickstart lever should return by itself (due to the spring return action).
This step is done with only two bolts holding the right hand crankcase (clutch) cover in place.
9. If kickstart still works properly, put in the remaining bolts for the right hand crankcase (clutch) cover. Re-check the bolt that holds the kickstart lever on for tightness (torque spec is 11 to 18 ft-lbs).
