Topic: CB550F kick starter doesn't disengage

[mtcr]

Hello all,

(I did try to search for this problem, but wasn't able to find anything. So I joined the forum to ask).

I have a CB550F (orange, barn find). The engine runs okay (will need a tuneup), but when the bike starts and runs I can hear the clicking of the kick starter, like it is partially engaged.

In neutral, the kickstarter ticks as the engine runs (makes more noise as you rev). In any other gear, it ticks according to how fast the rear wheel is moving. This makes me think that it doesn't completely disengage from the main transmission shaft when it is not being used (i.e. folded in, ready to ride).

The bike has around 95xx miles on it, and sat for a long time. Anyone else had this problem? Can it be fixed by removing the oil pan to reach the problem area, or does the engine have to be pulled?

I have experience building/repairing engines, I just want to triage this problem and see if it is a quick or extensive fix.

-Mike

[Nick0]

Is it possible that the PO installed it incorrectly before you bought it?


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[mtcr]

Is it possible that the PO installed it incorrectly before you bought it?

It is, but the lever fully returns to the stop position- if the PO installed it a spline or two off and it wasn't returning fully, that would make this a lot easier 

[mtcr]

Link to video of the problem
https://www.youtube.com/watch?v=96WQrdvGiWI&feature=youtu.be

I have done more research.

It sounds like part 18 and 20 (the kickstart pinion and ratchet, schematic below) rub. There is a spring that goes between the two (#19) that is either weakened or broken if my guess is correct. I really hope it is, as it would be a cheap fix.

The question is if I can get at the kickstart assembly from the oil pan side of the engine, and the picture that I've managed to find looks like I just might be able to. When I tackle this problem, I will post the progress of the fix.

[mtcr]

I found the problem and fixed it, and did not have to remove the engine to do so. Here is how:

1. Drained oil and removed oil pan
2. Removed header, muffler, kickstart lever and foot brake pedal
3. Removed clutch cover (nasty bolts taken care of with an impact wrench set to very low PSI)
4. Removed the larger cir clip (#43) and retaining spring (#24) on the exterior of the motor casing for the kick starter
5. Removed the cir clip inside the engine (#42)on the kickstart shaft - requires 90 degree cir clip pliers
6. Kickstart shaft pulls right out (make sure all parts are there)


Problem: Part #23 - the ratchet guide - was bent and was not completely disengaging the ratchet from the pinion. Additionally, the mating surfaces were rough and marred. I bent the retaining portion back to where it should be, and then polished the mating surfaces for smoother action.

Reinstallation:

As there are springs involved, it is difficult to perform the installation with the engine in the frame. However, there are two very helpful hints that I figured out while attempting it, and the only special tools required are a large and small vice-grip.

#1- when installing the kickstart shaft from the outside of the engine casing, there is nothing that keeps it in place. Therefore, attaching a vice-grip to it and wedging it to the frame works just fine. This could also be done with tape I suppose.
#2 - after all parts go on (except the main return spring), it is impossible to get everything to stay in place to get the cir clip back on inside the engine. To solve this, simply install everything except the last washer and cir clip (#29 and 42), then affix a small vice grip on the shaft in-between the gap on the retainer bracket (#23). This holds everything in place and allows you to install the smaller cir clip easily (if laying under a bike getting oil drips on your face is easy).

Long story short, it was a difficult fix to try and figure out for the first time. However, it would easy if I had to do it again. I don't know if anyone else has had a problem like this, but if they do, it can be fixed.

Remember to get new oil pan and clutch cover gaskets - they are not reusable and you're dead in the water if you forget to order them (heh).

-Mike

[Tews19]

I have mine engaging on my build but when I went to kick start it stayed down! DUH! Thanks for the write up as I will use this to follow. I have this same noise. It is honestly a blessing it is the kick starter and not something else in the engine.

[dave500]

great write up mtcr,could be in the tricks and tips section?

[Tews19]

Thanks for the write up once again! I attempted and successfully completed this this AM. Here are a few pics of before during and after for the process.