Kick starting problem?

[donjeske]

I have an (1970?) Ace 100 and am having problems with the kick start engaging the transmission. Normally I have put it in neutral, clutch handle disengaged and then kick start the bike. Now it just free spins and is not engaging. Here is the back story, I have just replaced my clutch discs as my issue before was that it would not disengage. The clutch seems to work now but this new problem has arrived.
Question: 1) Is there a torque on the clutch spindle nut?
Question: 2) Do I need to take out some spacers on the clutch?
Any other suggestions?

Her help is greatly appreciated.
Don

[dirtsquirt80]

Don can you bump start the bike? if so it might be the kick roll retainer its a common problem. Scott

[Dale]

Don,
The clutch nut torque spec for an Ace 100B is 250 in lb. Too much torque will mash the clutch pinion bushing.

Since your issue with the kick starter appeared after your work on the clutch pack, I would suspect that the problem is with the clutch pack. Either you mushroomed the pinion bushing or you might have left out (or used the incorrect) clutch thrust washer inner (904016) and/or the clutch thrust washer (904015). Both thrust washers are critical to the proper clutch operation.

Also note that the inner thrust washer is a thick washer that has a sharp edge on one side and rounded on the other. The rounded edge must face towards the engine. This washer can cup if not installed with the rounded edge facing in towards the engine.

Scott's question about bump starting will help determine if your clutch is engaged full time or not... I am guessing that it is engaged.
Dale

[donjeske]

I will make these checks and send some feed back Dale and Scott.

Some clarification is needed for a novice like myself, bump start is pushing the bike in gear to start it?
Thanks for the help!
Don

[Dale]

Yes, that is correct. Does pushing the bike, with it in gear, turn the motor over? And if so, will it start by pushing it?

P.S. I hope you have a kill switch... It is always a good idea to be able to shut a 2-stroke down in a hurry, should the need arise.
Dale

[donjeske]

Dale and Scott,
Success! I just rode my Ace 100 and it seems the kick start and clutch issue has been fixed thanks to your help.

Here was the solution: Reading your suggestions I remembered that I had added some outer clutch thrust washers (904015) to originally fix the clutch issue (Which turned out I just needed new clutch discs). I have been working on this for over a year so it had slipped my mind until you joggled it. I drained the gear box oil, pulled the gear cover and pulled two washers off (This is going by the 3/16" play recommendation). Once I got the gear cover on and oil to its normal level the kick start was fine. So long story short is that the kick start is fine and the clutch seems to be working as designed. I decided to do this check before I did the push start as I didn't want to damage anything.

Thanks again for the help,
Don

[Dale]

Don,
That is good news for sure. Just for clarification, did you have too many clutch disc spacers or extra outer clutch thrust washers? The clutch disc spacers are the large washers that fit inside the clutch disc on the outside of the clutch pack. These spacers come in .2, .3 and .5mm sizes. The outer clutch thrust washer fits between the clutch rotor gear and the clutch hub and is pretty easy to miss...
Glad you have had success.
Dale