Suzuki 2 Strokes

Hey there,

Just buttoned up the bottom end after installing a functional kickstart. Started moving the rods up and down to get the crankshaft moving, and I hear the tach drive gear clicking away. I know nothing about the t500. Just bought one with a busted kickstart because I wanted to get into old two-strokes. I opened her up before ever trying to bump-start her, so I have no idea if this tach clicking is a normal noise or not.

Pleaser point me in the right direction.
Andrew

The kick starter shaft has a worm gear that drives the worm shaft to spin the oil pump shaft. The other end of the oil pump shaft has a hole with a cut-out that takes the tacho cable. The tacho drive cable end has a small knob that sits in this cut-out. If you unscrew the tacho drive from the oil pump and the noise stops I'd suspect there is a faulty connection.


Cheers

Will Follow those very precise instructions this weekend, thanks Fritz!

I do have another question though, what if it's not the tach drive gear that's making the noise after all, but instead the new kick start that I installed?

Andrew

I've installed kick starters a few times and can't recall anything that would cause a clicking noise. Sorry I wish I could be more helpful.


Cheers


Geoff

There's nothing in the kickstart that would make a noise while rotating the crankshaft. Did you remove the oi pump when you split the cases? May be the oil pump is disengaged from the worm gear as Fritz said. Try turning the oil pump by hand (stick the tach cable in there and turn it) to see if it re-engages.

Jim

Jim,
Good point. You cannot safely rejoin the cases with the oil pump in place as there is a risk of the drive not fitting into the oil pump shaft slot.

Geoff

This should make things a bit more clear:

http://youtu.be/-p6Jh1D1sXU" onclick="window.open(this.href);return false;

The first, and louder, clicking is coming from the kick start. But, I think that it is occurring because I am rotating crank in the wrong direction. The second, and softer, type of clicking comes around when I reverse direction and spin the crank in the other (correct?) way. The second set of clicks comes from the stator assembly…

so, I should be good to drop it into the frame and get the top end suited up? Or, am I getting ahead of myself?

Thanks for the help everyone!
Andrew

FYI -at the 26 second mark I saw a bit of metal go by on the right crank wheel to the right of the con-rod. I don't recall any of my clicking like that when rotated backwards. Sorry to say it but I think you should open it up again and see what's going on.

Jim

Jim,

You have an eagle eye. But, it's not a metal flake. It's just a bit of threebond that got smeared. Bummed that I will have to split the cases again, I'm wondering if I purchased a faulty kick-start. Will post more videos soon.

Andrew

Hey guys,

Thanks so much for the help. Cracked the cases yesterday, in the end the kicker was just improperly installed (face-red).

Regards,
Andrew

andrewraffaele wrote:Hey guys,

Thanks so much for the help. Cracked the cases yesterday, in the end the kicker was just improperly installed (face-red).

Regards,
Andrew

Been there and done that repeatedly! We should have t-shirts made. Glad is was an easy fix.

Jim