T500 Kick starter question

[smokin_blue]

Hello, I have done some forum searching and haven't found a direct answer in this area so I will post and hope it hasn't been asked too many times before. I am looking at buying a T500. The owner says the only issue with it is that the kick starter doesn't always engage. Some times it catches some times it just slips or misses. I don't know if it is a miss-adjusted clutch or not. The bike is in a different town 6 hrs away so I haven't been able to see it yet for myself.

My question is other than a miss-adujsted clutch is there much else that goes wrong with them? What else should I be looking for during inspection? Should I be greatly concerned by this and avoid the bike if all else looks and sounds good?

[titan performance]

Opening the clutch will cause the kick starter to slip through without turning the motor, but I can't imagine the adjustment being out that much.....the bike would never move forward.
I have never personally had one fail completely, just the odd miss. It sounds more likely that there is a problem with the kick starter mechanism. You will want to buy it cheaply, as you may need to split the engine....

[smokin_blue]

Point made and taken.

If I was planning to split the cases anyway to go through the motor, and he was willing to throw in a replacement shaft/mechanism (he has may spares supposedly for the T500) do you think there is much other risk associated with this symptom?

thanks!

I will try to dig up the clutch adjustment procedure before I go look at it. It is possible it might not go forward very well. He bought it from a friend intending to restore it. He does many restores but has acquired another bike to do as well as taken on a job for another person so he was looking to make space. It may be possible the former owner miss adjusted the clutch at the cases and this is where it now sits.

[titan performance]

It seems unlikely to be any more than an issue with the kick starter to me, although someone more knowledgeable may know better. If you were planning to part the cases anyway, I wouldn't let the issue put me off the purchase if the price is right. I still doubt it's clutch adjustment, as if it were wrongly adjusted either on the cable or worm drive, the kicker would never work, not just intermittently.

[Pete O'Dell]

its the kick start pawl either sticking or worn, most likely the latter, engine split i'm afraid

[LexPaul]

I agree with Pete. I'm no expert, but if the bike can be roll started and it runs and shifts good, then I would factor in the 1500.00 rebuild rule for the kick starter, more if the guy won't produce a video. Have the guy post a you tube..

[smokin_blue]

Thanks for the input. Just one question. On your $1500 rule. Is that $1500 to do the actual rebuild or don't pay more than $1500 if you have to rebuild it.

thanks

[titan performance]

If the bike is running nicely, the job of fixing the kick start, although time consuming, is quite straight forward. They are pretty simple these old bikes. As long as nothing snaps, is siezed solid or is unobtainable.....you can pull the motor, split the cases, replace the broken parts and reassemble in a day no problem. I did exactly the same job on a Gt750, and was out on the bike that evening.
Of course barrels (jugs) corroded to studs, or stuck engine mount bolts will delay you big time.

[Ronin7]

Please post any resolution you have for the kickstart issue- I'm having the same problem and when I split the cases everything looks fine so I'm not sure what the issue is

[Pete O'Dell]

taken the pawl out and had a look??? examined the internal teeth?? checked the pawl button and spring are free??? because if the kick start is slipping and and lever/shaft splines are ok there is nothing else to go wrong

[Ronin7]

Sorry to hijack thread from the OP but I think our interests align-

If I post some pics of my kickstarter assembly (gear, pawl etc.) would that help? I'm not seeing anything that raises any red flags for why the mechanism isn't working.

[Vintageman]

I had same issue. And, it was the pawl. It had chipped its tooth so to speak. Still can buy from Suz for a couple bucks

But here is why think it happened with low mileage on the clock (<6000 Mile)
If the ignition is too advance the engine will kick back,putting high stress on the little pawl tooth.

I found my woodruff type keyway that holds the charging rotor magnet to crank was bent significantly and possibly the cause of too much advance. I have seen this before and by habit I always inspect those tiny little buggers

I have heard of a few people now finding low mile T500 with the Kick start issue. Bikes were in good shape at the time maybe, but too expensive to fix for the ownerand just stored it

You will have split cases and job is easy once there, The kicjer shaft is spring loaded a bit..., I think the T500 manual online (see Ozebook.com for example) shows exactly how to do the job.

[Pete O'Dell]

what can happen with bikes stored for a long time is the pawl sticks in the "open" or running position due to rust on either the pawl or the little button the spring that pushes it out, often a bang or too with a soft mallet on the clutch case will free it, worth a try before stripping it

[Vintageman]

Pete has a good point.

To be helpful in my case ( bad pawl tooth) you could feel it catch for sure, but with only very little torque it broke free and won't turn engine over with compression.

[smokin_blue]

Vintageman, that is exactly what this one does. I did end up buying the bike over Thanksgiving since we were near the town it was in (400 miles from home). So I now have my next project. I will let everyone know what I find but it will be a while before I delve into the engine. I have to finish my current project first. Also just in case anyone here has knowledge about Lyster frames let me know. I am working on aquiring one and if I can manage to get it titled for the road the goal will be to build a Lyster framed T500 racer for the street.

It feels good to have a two stroke again. If you want to see the orginal Smokin Blue go to my site at http://www.street-unique.com" onclick="window.open(this.href);return false; and look at the Smokin Blue page.

My current build I need to finish is here (it still needs paint and powder, and polish) http://suzukisavage.com/cgi-bin/YaBB.pl ... 4265/14#14" onclick="window.open(this.href);return false;

Thanks for all the help so far!