correct kick start lever installation

[captinr]

I just bought my first Hodaka, Dirt Squirt model 01. The bike is completely stock and original and runs great. PO removed kick starter for another bike. I purchased new replacement from SH. Can anyone explain correct installation procedure with regards to spring and pin orientation with the lever? Any help is apprectiated

[RichardMott]

Captinr,

You will need to remove the clutch cover in order to install the kick crank. I will give you a basic procedure, but there might be one here on the SH website. You do not need to drain the oil to do this, but need to take care in not damaging the gasket.

First, lay the bike down on its side carefully.
Next, remove the case screws. If you have an impact driver make sure you have the proper Phillips bit.
3. there is a pin that activates the clutch. it will more than likely drop out when you remove the cover. if not, remove it and put it somewhere save for reinstallation. A bit of grease will hold it in place when you re-install it.
4. if the spring and cover are installed, all you need to do is install the crank on the spline at the 2 O'clock position. Tighten the pinch bolt , then rotate it to the 11 O'clock position. This preloads the crank spring to return it to the stored position.
Hold it at the position with a large screw driver through the frame.
5. Grease the gasket and install the clutch pressure pin.
6. Install the clutch cover.
Remove the screw driver. This completes the procedure.
If I missed something, I am sure the group will correct me.

[jleewebb]

took a pic when I last did mine...click it for bigger pic...mirror helps...I always use my JIS (not exactly Phillips head) screwdriver on case screws...

[Zyx]

The original screws, so I hear, were JIS. Whether screws available these days are JIS or Phillips is anyone's guess, but I would guess Phillips, not JIS, the differences being largely esoteric. I have never seen JIS screws at the hardware or bike shop, and rarely see original, factory screws on any bike forty years old. But, if you have such a driver and it works, by all means use it.

I changed kick start levers for years without taking the side cover off, mostly because I didn't know you needed to. It is a pain In the butt to align the spring and lever with the spring under pressure, but it can be done.

[Bullfrog]

So far as I know, the original case screws were #3 Phillips - not JIS.
Ed.

[dirty_rat]

I have always been able to install the kicker without taking the clutch cover off, by removing the kick return rubber stopper. With that out of the way, you can install kicker without any tension on spring, them turn counterclockwise to put tension on the spring and get the kicker in the proper position. Then just put the rubber stopped back in.

[viclioce]

Don't know if you got it done yet but I have a spare kick start lever if you need one! ; D Victor