Engine/kickstart noise?

[motovespa]

Hi, I've been building my Polini 130cc engine for the last few weeks and finally managed to get the engine back in the frame and running last night but have a problem where it seems that the kickstart is not fully disengaging.
When it's running it makes a click-click-click sound like when the kickstart lever isn't pushed all the way up (but it is!)

Also, if I don't have the engine running but turn the flywheel by hand the click still happens, if I try to rotate it backwards it gives me more resistance like it trying to mesh with first gear or something?!

Has anybody encountered this before? I really don't want to have to split the cases again

It's a replacement kickstart quadrant if that makes any difference,
any help would be apprieciated.

Thanks,
Roger

[Juan]

I'd guess the spring isn't seated properly,did you change that along with the new quadrant?Sorry,looks like the cases need to come apart again.

[motovespa]

Thanks for the reply Juan,
It's still the original spring that I'm using, now that you mention it I wasn't 100% sure the spring was fully in the hole on the casing, I hope that's what it is because it should be an easy fix!

I've ordered one of the tools to seperate the engine casing, it was bloody expensive but should hopefully take some of the grief out of splitting the cases!

[hank]

motovespa said:

I've ordered one of the tools to seperate the engine casing, it was bloody expensive but should hopefully take some of the grief out of splitting the cases!

what tool we talking about

[motovespa]

It screws into the unused threads under the flywheel then I think as you tighten something down it forces the casings apart...

Here's how SIP describe it...

"Attach the three screws of the tool in the holes in the fly wheel cover, tighten them up. Now, screw the nut on the crank case screws, next pull off the dynamo. Hey, we´re almost finished! Now, fix the same three screws in the holes of the gear cover and pull out the crank case nice and easy. That´s all folks!"

I'm hoping it will fit smallframes and not just large frame engines!

[me]

I think thats for the PX engine........... as long as the clutch is removed you really shouldnt have any problems spliting the engine.
theres a shim that goes on the bearing before the spring (later models ) earlier were different with a nut and tab washers holding the clutch drum on to the caseing, these had a different arangement for the kickstart cog spring.
Sometimes the kickstart quadrant doesn't seat properly with the cog, because the buffers are to thick. (the ones that sit inside the caseings).

[motovespa]

me said:

I think thats for the PX engine...........

Doh! Ah well my next project will involve a PX engine so I'm sure the tool will come in handy at some point.

I have the later type floating kickstart gear with just the cup washer and the spring, I'm 99% sure that was put in ok though.

The main thing I worry about when splitting the cases is knocking the crank out of true if it gets a bit stuck in the bearings. I guess patience and a heatgun are the key ;D

[Juan]

motovespa said:

It's still the original spring that I'm using

It can be pot luck with old springs.I've had trouble with them in the past even when they seem in a good state or repair and plenty on tension.Other times they work fine. ::)Rule of thumb I tend to fit a new spring straight off these days.

[motovespa]

I split the cases last night and I think I've found the problem which is the xmas tree gear wasn't fully seated in it's bearing, the kickstart mechanism all looked ok.

I'll let you know if this fixes it once I get it all back together again!

Also, that engine separation tool is for large frame engines but you could use it with a small frame engine by utilising a couple of g-clamps.

Picked up an engine stand too, it makes things way easier! Money well spent!