he just got a 1995 jt 350 1st trials bike, starts and runs well, but kick start was flopping all over changed the kick start return spring but now its stiff and does not return just sits where its left when kicked. turned the bike off and moved the kicks start back but is very stiff to move by hand. any ideas what it is? oil levels good coolant levels good too. any simple solutions/ ideas to help? cheers Ryan

he just got a 1995 jt 350 1st trials bike, starts and runs well, but kick start was flopping all over changed the kick start return spring but now its stiff and does not return just sits where its left when kicked. turned the bike off and moved the kicks start back but is very stiff to move by hand. any ideas what it is? oil levels good coolant levels good too. any simple solutions/ ideas to help? cheers Ryan

I'm assuming you used a new sidecover gasket and re-installed the original thickness washer on the kickstart shaft and did not just use sealer (or another thicker washer), which will compress down and reduce the clearance between the shaft washer and the sidecover (and cause a stiff kickstart).

You might need to remove the sidecover and check if the shaft itself is binding or the binding happens when the sidecover is installed. If it is you will probably need to reverse the installation to see where the component is installed incorrectly.

Jon

I'm assuming you used a new sidecover gasket and re-installed the original thickness washer on the kickstart shaft and did not just use sealer (or another thicker washer), which will compress down and reduce the clearance between the shaft washer and the sidecover (and cause a stiff kickstart).

You might need to remove the sidecover and check if the shaft itself is binding or the binding happens when the sidecover is installed. If it is you will probably need to reverse the installation to see where the component is installed incorrectly.

Jon

Hi cheers the washer in there looked a lil home made any body know the correct thickness so I can see if its the correct 1?

cheers

hi had another look at the bike. the kick start has about 20degrees of freeish rotation, and then is stiff, do you think the kick start shaft might be bent?

hi had another look at the bike. the kick start has about 20degrees of freeish rotation, and then is stiff, do you think the kick start shaft might be bent?

I doubt the shaft is bent (it would take a massive amount of pressure to deform the short shaft) but there is the possibility that maybe something else in the system is bad, maybe a bearing on the gear or something?

A good way to tell how things go together is from the GasGas parts manuals (TrialsPartsUSA just added one for the 1991 model I see) but the parts lists also give the measurements for washers and bushings in most cases so if you have a suspect washer the last owner may have substituted, you can look up the washer in the parts list and it will usually give the measurements so you can check it to be sure.

Jon

Edited September 30, 201015 yr by JSE