Kickstart wonít move
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Hooked
1986 T5,1979 P200e
Joined: 30 Oct 2014
Posts: 419
Location: Oak Brook, Illinois
Mon Aug 12, 2019 12:48 pm quote
What did I do wrong.
Rebuilt this T5 motor because of a leaking clutch side seal. When I put the cases back together I put a bit of grease on the kickstart spring and on little kickstart gear.
Now Iíve installed the motor and the kickstart wonít move unless the clutch is disengaged.
The trans will still shift into all the gears.
I guess Iíll have to open up the motor again.

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Molto Verboso
1979 P150X, 1983 P200E, 1987 T5, 1996 PX200E, 2011 Yamaha Fazer 600 S2
Joined: 02 Aug 2015
Posts: 1526
Location: Veria, Greece
Mon Aug 12, 2019 1:43 pm quote
Since the kickstart works with the clutch disengaged, it's probably something related to the crank / piston. Can you rotate the flywheel??
Hooked
1986 T5,1979 P200e
Joined: 30 Oct 2014
Posts: 419
Location: Oak Brook, Illinois
Mon Aug 12, 2019 6:29 pm quote
You may be onto something SaFis, i went out tonight and I can rotate the flywheel with a ratchet and 19mm socket, but there is a lot of resistance at the top of its travel, almost as if the piston is making contact with something. I tried levering the kickstart as I used the ratchet and it moved just fine.
I did put new rings on the piston, but not sure thatís what is causing the problem.
Iíll pull the head and the cylinder tomorrow and hopefully all will be revealed.
Hooked
1986 T5,1979 P200e
Joined: 30 Oct 2014
Posts: 419
Location: Oak Brook, Illinois
Mon Aug 12, 2019 8:04 pm quote
I think i figured out the problem. I installed a new crank during the rebuild. I think itís possible the con-rod on the new crank is slightly longer than the old one. Maybe itís causing the piston to make contact with the head at the top of its travel.
Hooked
1986 T5,1979 P200e
Joined: 30 Oct 2014
Posts: 419
Location: Oak Brook, Illinois
Tue Aug 13, 2019 1:54 pm quote
I took off the head and everything freed up. I added a second cylinder gasket, (I had an old one) and put it all back together, and it started right up and runs well,
Except...the clutch (which I also rebuilt) wonít completely disengage. The cable is adjusted fine, but I have a hard time shifting into 3rd and 4th gear.
I partially dropped the motor and the clutch looks like it didnít spring back, I m going to remove it and try to figure out whatís wrong with it.

68B4BC82-3392-4F3D-A16C-DA1A90BA4946.jpeg

Hooked
1986 T5,1979 P200e
Joined: 30 Oct 2014
Posts: 419
Location: Oak Brook, Illinois
Tue Aug 13, 2019 2:18 pm quote
Tested the clutch on vise using a small socket as a plunger and the plates separated when I tightened the vise. So I guess the clutch is working.
Going to look at the parts diagram to make sure Iím not missing something.

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Hooked
1986 T5,1979 P200e
Joined: 30 Oct 2014
Posts: 419
Location: Oak Brook, Illinois
Fri Aug 16, 2019 7:05 am quote
Took out clutch and soaked the corks and plates, put it back in and the scooter shifts fine again. I had rebuilt the clutch 2 months ago and then wrapped it in an old shop rag, so maybe the plates dried out a bit and were sticking.
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