oops !!

[josh999]

Hello

After getting my Mini Melody ( eve smile ) home after 2 months of being at work in the garage.I was fininding it hard to start and the kickstart wouldent return the correct position, I found this

http://i1081.photobucket.com/albums/j35 ... kstart.jpg

http://i1081.photobucket.com/albums/j35 ... start1.jpg

http://i1081.photobucket.com/albums/j35 ... start2.jpg

Anybody got any ideas on what might have gone wrong to mess that up in such a bad way??

many thanks

Josh

[PolarIce]

Here you go... I fixed your image links....

Hello

After getting my Mini Melody ( eve smile ) home after 2 months of being at work in the garage.I was fininding it hard to start and the kickstart wouldent return the correct position, I found this







Anybody got any ideas on what might have gone wrong to mess that up in such a bad way??

many thanks

Josh

[josh999]

Cheers mate

How did you do that ??
What did I do wrong lol

[Bear45-70]

I would replace the gear it runs against too or chances are you will have the same issue again.

[PolarIce]

Cheers mate

How did you do that ??
What did I do wrong lol

When your posting... click the Img tab at the top and then cut/paste your link in-between those markers...

Easy Breezy...

[Trafficjamz]

Anybody got any ideas on what might have gone wrong to mess that up in such a bad way??

When you kick start the scooter, KARATE is not necessary

When you get this part replaced......Kickstart a little softer.

[Bear45-70]

Anybody got any ideas on what might have gone wrong to mess that up in such a bad way??

When you kick start the scooter, KARATE is not necessary

When you get this part replaced......Kickstart a little softer.

[eliteguy50]

Anybody got any ideas on what might have gone wrong to mess that up in such a bad way??

When you kick start the scooter, KARATE is not necessary

When you get this part replaced......Kickstart a little softer.

Start by applying pressure to engage the gears rather than jaming them together suddenly.

[josh999]

HaHa

Loved the Karate comment

IÔÇÖm not that rough I promise, I think it might have had some abuse at work while I was on sick leave. (probably trying to hotwire it or something stupid)

Anyways. . . I went outside to look at the scooter this morning and noticed that the half circle gear thing? Was catching the side of the engine casing?????

Anybody got a kick start diagram?? I think thereÔÇÖs a few bits missing ( washers ect ) I donÔÇÖt think the last guy put it back together properly

Cheers

[Wheelman-111]

Greetings:

If the half-moon is hitting the case, one of 2 things may be wrong.

1. If you're lucky, it's just an assembly issue. A snap-ring (circlip) holds the kickstart shaft in the correct position to keep it away from the case. If it's missing, the spindle slides outward and the half-moon hangs up.

2. More likely the bushing on which the spindle rotates has worn larger, perhaps with the spindle shaft itself worn smaller. As a result of a smaller shaft in bigger hole, the shaft no longer rotates about an axis but wobbles into a diagonal position, like this: |\| Instead of |||. The angle allows the half-moon to make contact.

Correct assembly procedures and all the needed parts are diagrammed in the Factory Service Manual available on this site. I suspect you'll be needing a few new parts to make this work right again.

[Saved]

That's a definite oops...

[noiseguy]

Check the assembly diagrams / microfiche to ensure you've got all the right parts in all the right places.

Gears don't usually chew up on one side like that. There should be matching damage on another surface. Look for it.

Doubtful case would have done that... steel gears win on Al castings. Either damage from kicking (misalign) or damage while running (grinding on something.)

[Wheelman-111]

Greetings:

Now that I can see the Bucket pics, I have a better idea:
It looks like the sliding spindle that engages the Drive Pulley didn't disengage for some reason. If so, that part is probably munged too, along with the Castle teeth on the spindle and perhaps the drive face as well.