August 3, 200818 yr ok guys this is my 1st post so go easy i tried to kick start my gas gas txt 200cc 2000 today when the kick start stopped at the first click when kicking, tried a few times but moved down slightly then wouldnt move any further down, very strange as it started an hour or two before that! also has anyone replaced headstock bearings? as i need to know how hard a job this would be cheers
August 4, 200818 yr Hi daz, It is quite likely that the 2 kickstart gears have given up. Some of the gears were not hardened sufficiently and after some time, the teeth would round off. Best to replace both of these gears, even if the damage looks like it is just on one gear, they are at the inside end of the kiskstart shaft. You will need to remove the clutch to get at this, to undo the clutch centre nut, try either an impact driver or air ratchet but not by using a socket with the clutch centre jammed to prevent it from turning with a screwdriver against the spring posts - they break easily. The taper bearings in the headstock are a common car wheel bearing size so you should have no trouble getting these. The bottom bearing inner race is a problem to remove, some people use a cold chisel to split this, you can also very carefully grind a deep slot across the race before splitting it away from the head stem. Re-fill with either 10 weight mineral oil, or an ATF rated to Dexron III, 700ml. Bye, PeterB.
August 4, 200818 yr Author Hi daz,It is quite likely that the 2 kickstart gears have given up. Some of the gears were not hardened sufficiently and after some time, the teeth would round off. Best to replace both of these gears, even if the damage looks like it is just on one gear, they are at the inside end of the kiskstart shaft. You will need to remove the clutch to get at this, to undo the clutch centre nut, try either an impact driver or air ratchet but not by using a socket with the clutch centre jammed to prevent it from turning with a screwdriver against the spring posts - they break easily. The taper bearings in the headstock are a common car wheel bearing size so you should have no trouble getting these. The bottom bearing inner race is a problem to remove, some people use a cold chisel to split this, you can also very carefully grind a deep slot across the race before splitting it away from the head stem. Re-fill with either 10 weight mineral oil, or an ATF rated to Dexron III, 700ml. Bye, PeterB. i will try that, thanks for your help
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