Josh - please take some pics and post, then tell us which folder you
posted them in.

Maybe someone can help you and maybe it;ll help someone later

Soup

--- In HuskyOwners@yahoogroups.com, Josh Felter <felter123@...> wrote:
>
> For some reason I cannot figure this out, The spring was definately
not in the correct place but I am sure it is now. Still not working.
The rest of the shifting mechanisms look OK as well. Maybe a little
wear. Does the U shaped spring wear out? Any other ideas? I can take
pictures of everything, maybe someone could diagnose? Any ideas would
be greatly appreciated, Thanks, Josh
>
> Steve Clark <steven_d_clark@...>
wrote: That "Hot start" idea is an
excellent idea!
>
> talk to you soon about Woodlands
>
> --- In HuskyOwners@yahoogroups.com, carlschuur@ wrote:
> >
> > Steve,
> >
> > I've been as sick as a dog the past 4 days, with a bad chest and
> head cold. I think I'm 'good-to-go' for Woodland on the 9th
though
> (don't care if I do hack out a lung). I'm going back to my snap-
> on/pop-off Harley compression release (I own 3 now) in my 430.
Did
> some testing with a compression gauge and found that it drops the
> kickstarting compression from 120 lbs, down to just 40. That
ought
> to help save the idler gear shaft from cracking out of the case on
a
> backfire. Usually fires on the third kick. I tried to make one
of
> them pass more air by drilling 2 extra vent holes, but the flow
rate
> is controlled/regulated internally, - nuts.
> >
> > I'm engineering some aluminum brackets to mount to the head so I
> can actuate it via a "hot start" lever and cable, rather than
having
> to reach back down to the head whenever the motor backfires.
> Planning to make it waterproof too. Makes for a busy weekend, but
> lots of fun. ;-)
> >
> > E-mail me, and we'll work out the details.
> >
> > C
> >
> >
> >
> > -------------- Original message --------------
> > From: Steve Clark <steven_d_clark@>
> >
> >
> >
> > Carl -
> >
> > how about putting some thought and effort into a response next
> time? ;-)
> >
> > hey - when we goin racin again?
> >
> >
> >
> >
> >
> > To: HuskyOwners@yahoogroups.com
> > From: stevenhusky21@
> > Date: Thu, 31 Jan 2008 00:22:40 +0000
> > Subject: [HuskyOwners] Re: Shifter not returning? Exploded view
of
> clutch side?
> >
> >
> > Carl,
> >
> > Thanks for the great information. I'm going to study the part
manual
> > and the information you sent me and maybe I can figure it out.
> Thanks
> > again for helping me out.
> > Steven M.
> >
> > --- In HuskyOwners@yahoogroups.com, carlschuur@ wrote:
> > >
> > > Steven,
> > >
> > > What your describing suggests to me that there is something
wrong
> > with the 'shoe' that controls the deployment of the spring-loaded
> > engagement pal. In other words, when the kickstarter is in the
> > resting position against the rubber block on the outside of the
> > primary cover, inside the cover the pal is supposed to be folded
> down
> > flat by the shoe. Otherwise, it's constantly wearing across the
> > notches on the inside of the kickstarter gear. As soon as you
shut
> > the motor off and the crank rolls backwards, - either from simple
> > compression, or a back-fire, the pal engages the next notch in
the
> > gear and cracks your case.
> > >
> > > Take a close look at the pal and the shoe. The shoe is
supposed to
> > have a "step" in it. As you move the kickstarter backwards into
> > kicking position, somewhere past vertical, the pal is supposed to
> > travel up the step in order to engage the notches on the inside
of
> the
> > kickstarter gear. Not sure how it happens, but sometimes the
step in
> > the shoe gets scraped off. Probably from a bad back-fire and/or a
> > poorly engaging/fittting pal. If it needs the step restored, you
can
> > either weld it up and grind and file the contour back in, or get
> > another shoe. I've noticed that the location of the step seems to
> > vary a bit in my motors ('81 -'85), but it's the contour of the
shoe
> > that determines the angle the kickstarter is at when it engages
the
> > engine Given that I'm tall, I've modified all of mine to allow
the
> > maximum amount of down-stroke. The other thing to watch for is
that
> > the return spring isn't holding the shaft to far out towards the
> > kickstarter gear. Did you take the shaft and sp
> > > ring out? If the spring isn't properly seated, the shaft won't
go
> > in to the primary cover far enough to allow the pal to engage the
> > shoe. This means the pal will be deployed all the time, wearing
> > against the notches, etc. (see above). In which case, you'll
> probably
> > have to remove and reinstall the spring.
> > >
> > > The easiest way I've found to do this is to take the kickstart
> lever
> > off of the hub/stub because it just seem s to get in my way.
Take
> the
> > circlip off the shaft, and carefully remove the hub/stub without
> > pushing down on the shaft. Using a 10 inch crescent, grab a hold
of
> > the pal mounting boss/area of the shaft, you can unwind the
spring
> by
> > first cranking in some tension , which in-turn frees up the pal
so
> it
> > can be removed. In other words, the pal also serves the ultimate
> > 'stop' for the system. Remove the pal and its tiny deployment
> spring.
> > Slowly unwind the spring with the crescent. Whatever you do,
don't
> > get your fingers whacked by the boss! It will split a fingernail
> like
> > kindling. Now you can push the shaft out. Remove the 2 Phillips
> > screws holding in the shoe, while being careful not lose the two
> > aluminum spacers underneath (note - if you don't have spacers,
> you'll
> > probably have the same engagement issues).
> > >
> > > The key to getting the spring all the way in is to install it
> > without allowing it to overlap/bind itself. Otherwise it won't
> > compress far enough into its space in the cover. The other thing
to
> > watch is that the right-angle bend at the end of the spring stays
> > properly hooked on the finger at the end of the shoe. So,
install
> the
> > spring into the finger on the shoe. Install them both into the
case
> > with blue Locktite on the screws, remembering the two aluminum
> spacers
> > under the shoe (countersunk area upward to screws; flat area to
> > cover). Install the shaft partially into the hole and engage the
> tine
> > from the spring-end into the hole in the pal boss. Using the
> > crescent, wind the spring by rotating the shaft backwards roughly
> > 3/4ths of a turn until the pal area is facing the shoe contour.
> Press
> > the shaft down into the cover without losing your hold with the
> > crescent. Reinstall the pal deployment spring and the pal. Unwind
> > the spring until the pal stops the travel against the shoe
> > > (the second step in the shoe). Carefully reinstall the
kickstarter
> > hub/stub and circlip without moving the shaft backwards, or else
the
> > pal will disengage. This would be bad, - very bad. Once it's back
> > together, carefully (fingers?/crescent wrench?) check that the
> > end-play between the kickstarter hub and the case isn't large
enough
> > to allow the shaft to float back into the case and disengage the
pal
> > (same bad things). Otherwise, you need a steel shim, or two to
fill
> > the void. Check that the pal smoothly follows the contour of the
> shoe
> > and deploys at a useful kickstarter angle. Lastly, when you
> reinstall
> > the primary cover with a new gasket, listen for scraping noises
when
> > you use the kickstarter. Same once the bike is running. The
reason I
> > say this is that my 510 needed a thicker gasket in order to keep
the
> > moving parts separated. Hope this helps.
> > >
> > > Good Luck,
> > >
> > > Carl S.
> > > Kent, WA
> > >
> > >
> > >
> > >
> > >
> > >
> > >
> > > -------------- Original message --------------
> > > From: "steven" <stevenhusky21@>
> > > Yes, I have the 83 part manual on CD but what I need are
> instruction
> > > on how to install the kick starter assembly. I took the kick
> starter
> > > gear and parts out and look at everything and it look fine but
> when
> > > ever I put it all back together the kick starter kick back
real
> hard
> > > against the case when I turn the motor off. The problem has to
be
> the
> > > way the pieces are a-line when I put the side cover back on. I
> think
> > > that the kick starter gear has to be turn to a certain point
> before
> > > the cover is put back on. The kick starter was working fine
> before the
> > > side cover was taken off last year.
> > > Steven
> > >
> > > --- In HuskyOwners@yahoogroups.com, Steve Clark
<steven_d_clark@>
> > > wrote:
> > > >
> > > >
> > > >
> > > > did you check the link to the 83 manual I sent? if that
doesn't
> > > cover it let me know
> > > >
> > > >
> > > > To: HuskyOwners@: stevenhusky21@: Tue, 29 Jan 2008 20:34:07
> > > +0000Subject: [HuskyOwners] Re: Shifter not returning?
Exploded
> view
> > > of clutch side?
> > > >
> > > >
> > > >
> > > >
> > > > Hello,Would you have any manual or pictures on how to
install
> the
> > > kickstarter? I have a 83 Husky WR250 and awhile back I took
off
> the
> > > leftside cover and when I put it back together it seem fine.
But
> when
> > > Iturn off the motor the kick starter lever kick back and crack
the
> > > sidecover where the lever rest. It did this twice and the crack
> > > isgetting wider. I don't want to ride it until I can get some
> > > diagramor manual showing how to put this together correctly. I
> had it
> > > off afew month back but couldn't see anything wrong with it.
> > > Thankseveryone for your help.Steven--- In
> HuskyOwners@yahoogroups.com,
> > > Jeff Osborn <jsozzborn@> wrote:>> Cool PDF Soup!> > Hey.....I
> have the
> > > same document for the 1981 Huskys as well as theworkshop
manual
> and
> > > engine disassembly....all 1981.> > Is this something that
would
> create
> > > interest or is it something youalready have?> > If there is
> interest,
> > > I will see about getting them scanned as PDF'Sand post them in
the
> > > files section.> > Regards,> > Jeff Osborn> 60J> > > To:
> HuskyOwners@:
> > > steven_d_clark@: Tue, 29 Jan 2008 17:56:33+0000Subject:
> [HuskyOwners]
> > > Re: Shifter not returning? Exploded viewof clutch side?> > > >
> >
> > > http://www.soups-kitchen.com/Husky%20Parts%20Lists/83-husky-
> parts.pdf>
> > > > --- In HuskyOwners@yahoogroups.com, Steve Clark
> > > <steven_d_clark@>wrote:>> > Try
> > >
> > here>http://www.soups-kitchen.com/Husky%20Parts%20Lists/83-husky-
> parts.pdf>>
> > > > > > To: HuskyOwners@: felter123@: Tue, 29 Jan 2008
> > > 02:31:50+0000Subject: [HuskyOwners] Shifter not returning?
> Exploded
> > > view ofclutch side?> > > > > The 1983 Husky CR500 I recently
> bought
> > > and amgoing over has a few quirks left to work out, shifting
is
> the
> > > latest.The shifter won't return after it shifts, I am thinking
the
> > > dummy thathad it before me put it together wrong after
installing
> a
> > > new clutch.Does anyone have the exploded view from the clutch
> side? I
> > > am reallyhoping that the tranny is okay as I have already had
> > > enoughdisappointment with this bike. I popped the cover off
today
> and
> > > amunsure where one spring goes. It was just hanging off the
> > > shiftermechanism on the inside. Any help will be great!!
thanks a
> lot,
> > > Josh >> > > > >
> > >
> >__________________________________________________________>Connect
> > > and share in new ways with Windows
> > >
> > Live.>http://www.windowslive.com/share.html?
> ocid=TXT_TAGHM_Wave2_sharelife_012008>>
> > > > > > > > > >
> > > __________________________________________________________>
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> > > >
> > > >
> > > >
> > > >
> > > > __________________________________________________________
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