I need to know how to install the kick start spring assembly
SOURCE: would like to know if you need to wind the spring on kick starter
There should be some tension on the spring. You may not have the spring positioned correctly as you shouldn't have to wind it around.
SOURCE: I need to know how to assemble a Kick Start mechanism
Google " Kawasaki KX 80 service manual " You can down load PDF manuals for low cost or get one by ordering. You might want to check out your local library. They somtimes get manuals given to them. It has been 30 years since I have worked as a Kawasaki mechanic but I MAY ( or may not ), be able to help if you could email a clear photo of the parts you have and a clear photo of the inside of the outer case plus a photo of the right inner caseing preferably with the clutch removed.
SOURCE: how to put the kick start assembly on my 2000 ttr
Go to the site below where you can see a parts diagram for your specific bike. Often seeing a diagram can help determining how it goes back together. You will select the actual brand, year, model, etc., once you go to the site. Part numbers and prices are also shown. You can order parts from this site. In the event no price is shown on a particular part and/or the notation "Not Available" is in the description, the part is not in stock. www.babbittsonline.com/pages/parts/viewbybrandand/parts.aspx
Basically you put the shaft into the center case, put the clip on the gear, put the gear on the shaft and rotate the clip into the spot provided below the shaft, mount the large washer, mount the spring guide collar, put the center of the spring into the end of the spring guide notch while the long spring extension hooks into the place provided in the center case. Now put the cover back on with the seal already mounted in the cover. Can I get a “very helpful” rating on this answer?
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SOURCE: 1980 Yamaha xs 400. First start of the spring.
Kick it on the otherside,,,,,, Perhaps your starter motor brushes got jammed, well off to a repair shop or if daring take that motor apart.
SOURCE: 1980 Yamaha xs 400. First start of the spring.
Sounds like it either dropped a valve, or broke a Connecting Rod. It is never good to get the RPM's too high on the first start. If you have to get them up high to keep it running, you probably have build up in the carb. Make sure it is in Neutral, and the first thing I would do is check the valves. Lift the valve cover off and see if any of them are missing. If not, unscrew the side cover on the left side of the bike(1 inch round cover using a flat tip screw dirver) and the nut in there that is exposed, try to turn it with a ratchet. If you cannot, pull the spark plug and using a pick up magnet, run it down the hole, swish it around a little, pull it out and see if you picked up anything. Last thing I can think of is drain your oil, and see if any metal comes out there, if not, your going to probably be rebuilding. It's not as expensive as it sounds if you do most of the work yourself and pay close attention to your service manual. If you need one, I can send you a digital copy for $30, or a grease proof binder and CD for $100.
Good luck.
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