Slugging starter

[furiousbob]

On my 2003 Zuma 50, I've always had a sluggish starter when the motor's cold.  It always requires a kick start.  Once it's warmed up, though, starts just fine.

So I started throwing parts at it.  New starter and new battery.  Problem persists.  I took the CVT cover off to inspect and clean the bendix gear.  Seemed to be working okay.  I ran the starter without the gear in.  Starter turns just fine.  After reinstalling the cleaned bendix gear, I tried starting it.  Voila!  Works great... that is until I put the CVT cover back on.  Goes right back to sluggish starting.

What am I missing here?  I did remove the CVT gasket some years ago and never bothered to put another one in.  Could the lack of a gasket mess with the kick starter pawl's placement and prevent electric starts?  I'm a bit confused.

[aeroxbud]

I have seen it cause problems not using a gasket before. It can put pressure on the kick start gear requiring more force to turn.
It would be easy to see if it is your problem by putting a few washers between the case and CVT cover.
My wife's Aprilia wouldn't even kick over without the gasket when she brought it.

[yambw’s]

I have had the slow starter on a couple of minarellis in the past, I have had good results with stripping the starter clutch down and getting it all super clean then just lubing everything with silicone spray