kick start gear interference

[fuzzyruttin]

Got the Polini variator installed (150 GY6), started up, and did some test runs a couple weeks ago. Later I find that the kick start is locked into one position and won't budge. After examining the problem this evening, I notice the kick start gears are out of harms way in the stowed position, but interfere with the Polini variator fins when the kick start is engaged.

Stowed position:




Engaged:




Is this a known problem with this particular upgrade?

Bigger question is, what do I do now, go without a kick start? It saved my ass a couple times last year, so I feel a bit naked without it. I really don't wanna file down the variator fins, not only on account of screwing up the balance (hopefully it's not badly damaged already) but, like, it's a nice piece that I paid top dollar for, right??

Maybe I need a new kick start gear? As in, continue stripping off the chinese heritage POS parts and get something made in Taiwan, perhaps, if there is such a thing?

Are there any alternatives to starting the scoot if your battery is dead or if you have other mechanical issues?

[pinkscoot]

The 150 GY6 I owned the kick starter quit working early on. I just made sure the battery was charged and the engine was in good tune. My Aprilia Scarabeo 150 has no kick starter on it. Same thing, good battery and good tune on the engine.

[fuzzyruttin]

Good battery, good tune, yes. Last year I left the ignition turned on overnight, and kick started the bike in the morning because the battery was dead. To top it off, the knock-off carb that I was running bogged horrible on initial throttle, and the bike always wanted to stall out unless you had a good sense of engine's state at the very second you wanted to launch. I used to rev like a harley a lot, the very thing that annoys me most sitting at a light. Anyway, couple that with a dead battery, and I really wore myself out kicking. Plus unbeknownst to me, a kick start bushing was missing, which complicated matters ever more. There were a few choice words that day. After tending the battery it was ok, but man.

Soo... is there any harm in jump starting a scooter with a car? Should the car's engine be turned off, or any other precautions?

And another gremlin - toward the end of last year, the starter began making an awful screech sound. I assume there's something up with the bendix (?) but even if the engine doesn't start, there's a loud nasty screech. Your reflex is to quickly let go of the starter button. It doesn't always occur though. I've started the bike maybe a dozen times this year for tuning/testing, and it screeched once. Point is, if the starter decides to up n keel over, I'd be S.O.L. without a kick start.

[snaker]

Step one would be to put the proper parts in obviously.
If your willing to chop a bit and sacrifice other parts to save that pulley then:
If the dimensions would work out you could grind down the drive gear where it is hitting.
I think you could grind to the channel that the wire clip sits in, taking as little as possible.
If the wire clip also interferes then you will be looking at a larger project.
Look that area over closely and give some pictures.

[fuzzyruttin]

Feb 14, 2019 12:56:43 GMT -5 snaker said:

If the dimensions would work out you could grind down the drive gear where it is hitting.
I think you could grind to the channel that the wire clip sits in, taking as little as possible.

Yep, I get what you're saying. It would take some trial and error on account of not being able to get an accurate measurement on the impact zone, but it looks like 1mm or less would do it. The problem is figuring a way to get an even grind all the way around the retainer, especially assuming the gear is made of some pretty hard steal. Believe it or not, I have been living all my life without ever having owned a bench vise. If could put the spindle in the vise and rotate the gear while dremeling the outer circumference of the retainer, that would probably get the job done without looking too sloppy. Well, looks like I'm off to the hardware store. 


Variator impact zone:




Grind the circumference of the spring retainer here:

[fuzzyruttin]

Got the vise.

Before:




After, I used the dot as a cutting reference.

[fuzzyruttin]

Dang. It's still grinding on the variator fins. The spring retainer is not the issue now, it's the clip.

Good retainer clearance (hard to see unless you zoom in):




Clip wear:







Done for the evening. I've been tooling around since the break of dawn. Guess I'll have to grind into the clip next, or get into the variator fins, which I am really trying to avoid.

[06gix]

Did you at least get some gains?

[fuzzyruttin]

Forgot to take final pic, but basically ground/filed down the clip at the wear mark. I removed quite a bit without compromising structural integrity. It all works nice now, no grinding or binding when kick starting.

[fuzzyruttin]

Feb 21, 2019 23:33:12 GMT -5 06gix said:

Did you at least get some gains?

Low speed RPMs ramp up pretty good and level off with speed. RPMs also increase smoothly as throttle is opened while cruising, 30 mph for example. WOT at speed, it runs at 7800 RPM, which is just about right. Previously in fighting with the stock variator, I installed one belt size longer in attempt to get better top speed. So I ordered and just received the standard belt size since the bike doesn't seem to be hitting that top speed anymore. Granted I also installed a new carb that is not quite perfectly tuned yet either. There are a couple variables going on (broke the cardinal rule "only change one thing at a time") but the variator definitely runs smoother, as in, it is receptive to throttle response and has improved acceleration it seems. Sorry, nothing scientific, but I like it.

[snaker]

Top shelf mod. Congrats