lineaway

Just a thought. It sounds like the issue is when hot. I would try your brothers coil again, but give it a good 30 minute ride. Still interesting that your father in law can get it to go. So what ever the problem, is not completely broke. Which makes it very hard to find.

You have a few things against you. My sons bike is the same for me. He starts it easily, I have to get it all right or it will not go. Try moving the kicker forward one tooth on the shaft. You also need it to be top dead center when you kick it. Our bike started doing this after it got hot when the fan went. I`m assuming we lost some compression and could use a fresh piston and rings. If your bike can be started by someone else, then it is not an electrical problem.

Just the crank alone should have spun fairly free.

Do you already have the clutch (primary gear) in place? And why the rebuild in the first place? Just trying to under stand where you are at with this.

Since chasing all these symptoms have you tried changing to fresh fuel? Bad fuel can make a bike run just like this!

Good brakes.(But no brake rod) NICE!

Bearings in the case first? Bearings have to be on the shaft all the way and centered.

IRC would be best.

Also do you have the transmission in neutral?

Crank and trans two different issues.

You do not have the crank pressed all the way on the bearing/and or centered. You might get by with a couple of well placed hits with a mallet on the end of the crank. Do not screw up the threads in haste.

Clutch drag and not releasing when disengaged is not the same issue. Nothing worse than pulling in the clutch and it `works` 1/2 a second after it should. The problem from cold on the first ride of the day has always been around. But the issue of it not working once warmed up can be the master cylinder or slave cylinder. Also is the fluid low? Or it could just be poorly adjusted. If you have the lever adjusted in too far, the piston is not traveling it`s full stroke. Make sure there is some play at the lever. Could be as simple as a rebuild kit for the master cylinder. As Billy said (Thanks Billy great post) you have to figure out what system is not working.

Being the bike is 10 years old the master cylinder could be the problem. Also you are using 500cc of oil?

Glad you have it back together. It`s hard to imagine the kick start pawl is not damaged after looking the idler gear.

Between 7-8 should be floating wheelies or turns. Lost technique with all the hopping. Watching a top rider do a proper floating turn is a lost art. Practice both directions. With all the `No stop` riding, this is the one that separates the riders.

You might try unplugging the cdi. They do not fit very well and just plug back in. If you cannot get any parts from RSI, I just checked my tool box and still have a cdi for it. (They were a known problem back then.) Hopefully it is something simple.

Check every spoke hole in the hubs front and back, as they were prone to cracking. Great vintage bike.

I`ve seen more `04`s crack the cases than other years. That is too much play in the shaft. The shaft should be fairly tight before closing with cover. It can be very hard to get the kick start shaft into place. There is a blind bearing that could need replacing on the other end. A good chance you will need a whole new shaft as this has been updated several times. Take your time and get it right or it can happen again. Also if you have a riding buddy familiar with this it is worthwhile to get some help. A good friend broke his just as he started a national a few years back. Luckily I had a later start time and the importer had the parts available. 45 minutes later we had new case, gears and shaft replaced. We both finished with plenty of time. Good luck.

Mitch, the confusing thing on the cadet is the engine started out a 50. Was bumped to 68cc, hence the txt70, then stroked to 72.5cc. The 50 class is small wheel only. (Not for the cadet) This bike fits in two other classes. Great little bike, but did not know they made an 80 kit. The boy always had an 80 kit available.

Raga certainly fived that. The observer should have took control by hinting at the yellow card. Minder and rider would have promptly cleared the section.

Nelly, yeah typing and drinking is not one of my strong points!

www.trialspartsusa.com/tech.html has a suspension break down. Looks like you just remove bottom leg bolt, then cap and rod assembly just pulls out.

At least we had a championship. The last trial had a reason to run, in quite a few positions. And it was not ever called no-stop.

The engine has always lacked lower grunt. Best thing to do, is for the boy to start learning proper clutch control. Myself I would just leave the bike alone till you are ready for a 125. It`s always been a great starter bike. The new ones are supposed to have a new motor, interesting to see why.

Hate to say on most OEM parts, you have to do it the old fashioned way. Pick up the phone, call a dealer and ask to talk to the parts dept. Actually it`s in your best interest. You might get the correct parts the first time.