Page 1 of 2 12 LastLast
Results 1 to 15 of 19

Thread: Cant get kick start gear to engage with crank

  1. #1
    apriliaforum newb
    Join Date
    May 2009
    Posts
    14

    Cant get kick start gear to engage with crank

    Hi guys,

    I have a 1998 Sr50lc which im currently restoring. It was my first bike and I sold it after about a year and bought it back recently as a non runner. The guy destroyed the crank and many other bits.

    Problem is, I have installed a 70cc malossi kit, and the compression is too high for the electric start, so I have to use the kick start, but I cant get the gear on the kick cover to engage with the gear on the end og the crank. Maybe im putting it together wrong. This is how I have put it together:

    Oh and the starter clutch is already on the crank and in place correctly.

    The kick cover gear, the crank gear (toothed bit at the end of the crank) and the check plate are all brand new. I just cant get the two gears to come together.

    All help appreciated, thanks!







  2. #2
    apriliaforum expert ReplicaOwner's Avatar
    Join Date
    Jun 2008
    Location
    Southeast Indiana USA
    Posts
    913
    Maybe clean and lube the shaft there in the last pic. When you go to move the kick start it pushes the gear out into the piece on the crank.
    2000 SR50 Replica #1
    Minarelli 2-Stroke LC
    Martin Racing 72cc Big Bore Kit
    Ceramic Leo Vince ZX Exhaust Pipe
    Gates Powerlink Drive Belt
    4.3 gram Leo Roller Weights
    Yellow Leo Vince Clutch Springs
    Uni-Filter Two-Stage Pod Filter
    Martin Racing Dual Stage Fiber Reeds
    Martin Racing Aluminum Intake, Ported & Polished
    Tireflys Flashing Valve Stem Lights
    Fiber Optic Accent Lights On Belly Pan
    Needle E-Clip on 4th Notch - #115 Jet
    55+ mph on Flat, 62mph in a draft
    Old and New Start Up Video
    Work In Progress...

  3. #3
    apriliaforum newb
    Join Date
    May 2009
    Posts
    14
    Thanks for that advice. I gave it a little rub with some wire wool and then put some copper grease on it. But still no luck. I really dont understand what im doing wrong. I dont think it is a problem from the crank side as the cog on the end of the crank uses up the last of the splines so it is spaced out to the max. It has to be somthing on the kick cover side.

    I have also tried a shim (an old brake line copper washer I had lying around), but still no good either.

    I also compared both the cog on the end of the crank and the one on the kick cover to the old worn ones i took off, but they are all the same thickness. I tried the old ones back on but still no luck.

    So frustrating!!

  4. #4
    apriliaforum newb
    Join Date
    May 2009
    Posts
    14
    Just had a think about this, would it be possible for the crank to be off centre a bit in the cases and thus the crank is sitting in a little on the variator side???

    Just a thought?

    I have put a new crank in, but as far as I can remember it should be tight on both cases.

    Its a brand new crank, new bearings and oil seals and has never been started yet. As the compression is higher with the 70cc kit, the starter cant turn it over all that well. I removed the spark plug last night to give it a little help, but it still has trouble turning it over. The starter should be able to turn it over when the spark plug is out shouldnt it......? This is making be think that something is binding but what it would be I dont know.....?

  5. #5
    apriliaforum expert ReplicaOwner's Avatar
    Join Date
    Jun 2008
    Location
    Southeast Indiana USA
    Posts
    913
    Can you turn it over by hand with the sparkplug out?
    Also if you move the kickstarter by hand with the cover off, does it try to throw the gear off the shaft?
    2000 SR50 Replica #1
    Minarelli 2-Stroke LC
    Martin Racing 72cc Big Bore Kit
    Ceramic Leo Vince ZX Exhaust Pipe
    Gates Powerlink Drive Belt
    4.3 gram Leo Roller Weights
    Yellow Leo Vince Clutch Springs
    Uni-Filter Two-Stage Pod Filter
    Martin Racing Dual Stage Fiber Reeds
    Martin Racing Aluminum Intake, Ported & Polished
    Tireflys Flashing Valve Stem Lights
    Fiber Optic Accent Lights On Belly Pan
    Needle E-Clip on 4th Notch - #115 Jet
    55+ mph on Flat, 62mph in a draft
    Old and New Start Up Video
    Work In Progress...

  6. #6
    apriliaforum newb
    Join Date
    May 2009
    Posts
    14
    The gear does try to move off the shaft (which is what its meant to do I gather).

    I can turn ot over with the outer variator plate on, but I suppose a little tight maybe?

    Im beginning to think the crank is off centre, how would I rectify that?

  7. #7
    apriliaforum expert ReplicaOwner's Avatar
    Join Date
    Jun 2008
    Location
    Southeast Indiana USA
    Posts
    913
    Yes thats how the gear works. You said you already replaced the crank part of the starter gear didn't ya?
    If the crank was that far off center the piston and rod wouldn't line up.
    2000 SR50 Replica #1
    Minarelli 2-Stroke LC
    Martin Racing 72cc Big Bore Kit
    Ceramic Leo Vince ZX Exhaust Pipe
    Gates Powerlink Drive Belt
    4.3 gram Leo Roller Weights
    Yellow Leo Vince Clutch Springs
    Uni-Filter Two-Stage Pod Filter
    Martin Racing Dual Stage Fiber Reeds
    Martin Racing Aluminum Intake, Ported & Polished
    Tireflys Flashing Valve Stem Lights
    Fiber Optic Accent Lights On Belly Pan
    Needle E-Clip on 4th Notch - #115 Jet
    55+ mph on Flat, 62mph in a draft
    Old and New Start Up Video
    Work In Progress...

  8. #8
    apriliaforum newb
    Join Date
    May 2009
    Posts
    14
    Yeh I replaced both gears.

    Would it not still be possible for the crank to be a little off centre, 2-3mm?? It would explain why the kick cover gear wont engage with the crank gear.

    Is there a guide anywhere on how to install a crank???


    Thanks

    Ryan

  9. #9
    apriliaforum expert ReplicaOwner's Avatar
    Join Date
    Jun 2008
    Location
    Southeast Indiana USA
    Posts
    913
    I have the Minarelli engine service manual. Will that help?
    2000 SR50 Replica #1
    Minarelli 2-Stroke LC
    Martin Racing 72cc Big Bore Kit
    Ceramic Leo Vince ZX Exhaust Pipe
    Gates Powerlink Drive Belt
    4.3 gram Leo Roller Weights
    Yellow Leo Vince Clutch Springs
    Uni-Filter Two-Stage Pod Filter
    Martin Racing Dual Stage Fiber Reeds
    Martin Racing Aluminum Intake, Ported & Polished
    Tireflys Flashing Valve Stem Lights
    Fiber Optic Accent Lights On Belly Pan
    Needle E-Clip on 4th Notch - #115 Jet
    55+ mph on Flat, 62mph in a draft
    Old and New Start Up Video
    Work In Progress...

  10. #10
    apriliaforum expert ReplicaOwner's Avatar
    Join Date
    Jun 2008
    Location
    Southeast Indiana USA
    Posts
    913
    Quote Originally Posted by ReplicaOwner View Post
    I have the Minarelli engine service manual. Will that help?
    http://www.apriliaforum.com/forums/s....php?p=2171182
    2000 SR50 Replica #1
    Minarelli 2-Stroke LC
    Martin Racing 72cc Big Bore Kit
    Ceramic Leo Vince ZX Exhaust Pipe
    Gates Powerlink Drive Belt
    4.3 gram Leo Roller Weights
    Yellow Leo Vince Clutch Springs
    Uni-Filter Two-Stage Pod Filter
    Martin Racing Dual Stage Fiber Reeds
    Martin Racing Aluminum Intake, Ported & Polished
    Tireflys Flashing Valve Stem Lights
    Fiber Optic Accent Lights On Belly Pan
    Needle E-Clip on 4th Notch - #115 Jet
    55+ mph on Flat, 62mph in a draft
    Old and New Start Up Video
    Work In Progress...

  11. #11
    apriliaforum newb
    Join Date
    May 2009
    Posts
    14
    Hi guys, I still have this little bike, stripped it all back last year and decided to rebuild and finish, though still having this issue. It is extremely frustrating as I cant see what im doing wrong - any idea guys?

  12. #12
    apriliaforum Junkie 2Strokesforlife's Avatar
    Join Date
    Aug 2016
    Location
    Jenison, Michigan
    Posts
    317
    The engine should easily spin with no spark plug in it. If not, something is not right. I have a 70cc kit in my DiTech and the electric start has zero issues with turning the engine over. When I did my crank, and the cases were all tightened up, I gave each end of the crank a whack with a deadblow hammer (so the threads didn't get damaged) and it spun real easy after that. After 8 years, you'd think someone would have helped figure it out...
    2009 SR 50 Factory
    Malossi 70cc BBK
    Malossi HPC Crankshaft
    Stage6 Waterpump Impeller
    Arrow Extreme Pipe
    Malossi VL 13
    Ecu De-restricted 2.8.0
    7 Gram Dr. Pulley Sliders
    Stage6 Soft Contra Spring
    Water Trap
    RS 24/10
    Stage6 260mm Front Brake
    Stage6 Torque Control MKII 107mm
    Stage6 R/T Clutch Bell 460g
    Malossi Special Belt
    Malossi E5 Air Filter
    Stock Gears Installed

  13. #13
    apriliaforum Junkie 2Strokesforlife's Avatar
    Join Date
    Aug 2016
    Location
    Jenison, Michigan
    Posts
    317
    Click image for larger version. 

Name:	20170215_174553_1487199459343.jpg 
Views:	5 
Size:	493.8 KB 
ID:	326816
    It looks like everything for your variator is there, are you missing any spacers? #5?
    2009 SR 50 Factory
    Malossi 70cc BBK
    Malossi HPC Crankshaft
    Stage6 Waterpump Impeller
    Arrow Extreme Pipe
    Malossi VL 13
    Ecu De-restricted 2.8.0
    7 Gram Dr. Pulley Sliders
    Stage6 Soft Contra Spring
    Water Trap
    RS 24/10
    Stage6 260mm Front Brake
    Stage6 Torque Control MKII 107mm
    Stage6 R/T Clutch Bell 460g
    Malossi Special Belt
    Malossi E5 Air Filter
    Stock Gears Installed

  14. #14
    apriliaforum Junkie 2Strokesforlife's Avatar
    Join Date
    Aug 2016
    Location
    Jenison, Michigan
    Posts
    317
    Click image for larger version. 

Name:	20170215_174658_1487199608257.jpg 
Views:	2 
Size:	491.5 KB 
ID:	326850
    Don't worry about #11, it's a restriction.
    Last edited by 2Strokesforlife; 02-16-2017 at 05:59 AM.
    2009 SR 50 Factory
    Malossi 70cc BBK
    Malossi HPC Crankshaft
    Stage6 Waterpump Impeller
    Arrow Extreme Pipe
    Malossi VL 13
    Ecu De-restricted 2.8.0
    7 Gram Dr. Pulley Sliders
    Stage6 Soft Contra Spring
    Water Trap
    RS 24/10
    Stage6 260mm Front Brake
    Stage6 Torque Control MKII 107mm
    Stage6 R/T Clutch Bell 460g
    Malossi Special Belt
    Malossi E5 Air Filter
    Stock Gears Installed

  15. #15
    apriliaforum newb
    Join Date
    May 2009
    Posts
    14
    I hear ya, it was a project that never got finished, getting married, new house kid, etc it got put to the side so just resurrecting it, will finish it this time..... 8 years on just .....

Page 1 of 2 12 LastLast

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •