Topic: 74 CB 750 Recent rebuild leads to frozen kickstart

[thegoodlife]

Im very new here and managed to get by with a good friends help and Honda mans book. It all started with replacing second gear during the early winter. Previous owner must have loved to power shift and the lack of second was killing me as a novice rider. A good pal of mine helped me during the tear down and we replaced the piston rings, honed the cylinders, and tuned the valves on the top end. Replaced the shift drum and forks with a newer pair. After cleaning the carbs thoroughly and being patient with reinstalling the clutch we tried turning it over. Drained one battery and I dropped in a fresh new one the next day to have the same issue. My biggest concern is the starter seems fine and strong along with the battery and carbs. I cannot for the life of me understand why the kickstart is frozen unless i press the electric start in which the kickstart free's and can be kicked but only half way. After months of slow and steady work I am learning my lesson that these old bikes can surprise you every step of the way. When the case was split I made sure to leave the kickstarter and spring alone. Im now worried that this could be an issue with the transmission it-self. Any thoughts would really help cause im shooting in the dark now and really concerned that if the bike does start will the transmission be okay since the kickstart is locked and more importantly whats my next step besides going back and cracking the case again?

[mcswny]

I was the good buddy helping here, so very vested in this issue. I didn't touch the bottom end, only the top (hehehe).

1. Even though the kick wasn't touched could something "down the line" in the transmission affect it?

2. OR my second guess, could when Robert (thegoodlife) installed the clutch basket shifted something, causing something to block the kick (or are they two 100% different mechanisms?)

What's weird, like he said, is when you push the started button, it frees the kick?

Any help would be amazing, unfortuantely we do understand the worst case scenario is re-pulling the engine (actually theres always an even worse case, ha), but maybe, just maybe, its a clutch interference.

[enwri]

Best not to start it just yet, the starter might be strong enough to overcome any friction that makes it seem locked up with the kickstart.
Could friction weld something solid, or machine it's own clearance, or just break something.
Check how the clutch is assembled first,, undo the big nut in the middle and see if it frees up at all. easier than splitting it open straight away, and you can check the kickgear with the clutch off.

[Restoration Fan]

I would imagine your problem is due to the gear on the kick starter not disengaging. 
Before you split the cases, try taking a rubber mallet and tapping firmly (but not slamming it) the kick starter gear towards the engine.  That gear rod is held in place by the pin that is shaped like a cylindrical C and is a pain in the buttocks to get out.  But it also will allow a bit of slop in some instances.  By tapping it back toward the engine, it might reseat the gear.

If that doesn't fix the issue then I agree with the sentiment to not crank it anymore without finding out what's going on.  You really don't want to make it seize the motor if there's an issue.  So at that point, you're talking removal of the engine from the frame.  Then turn it upside down and remove the lower case.  That will allow you access to the kick starter gear, spring and assembly.

[thegoodlife]

enwri & Restoration Fan thanks for the advice. Im going to try and take the time this evening and pull out the clutch completely. Then try the rubber mallet option you just suggested. Will post back any progress I make. Really crossing my toes I don't have to crack that case again. One way or another im going to bring this old girl back to life.

[mcswny]

Interesting. Thanks guys!

[mcswny]

enwri & Restoration Fan thanks for the advice. Im going to try and take the time this evening and pull out the clutch completely. Then try the rubber mallet option you just suggested. Will post back any progress I make. Really crossing my toes I don't have to crack that case again. One way or another im going to bring this old girl back to life.

Any luck?

[eshumaker]

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