Finally got my Ct3 clutch figured out and back together. After putting the side cover on i am having trouble with the kick starter.
The machine kicks over and the return spring works but if the kick starter snaps back up it doesnt stop where it should. I can rotate the starter  past where it should stop by pushing on it. What am I missing?



 

        


Hope this helps       

thanks for the great photo explanation, thought i had this correct but guess ill need to pull it apart and check

Also make sure that the kickstart shaft is pushed all of the way in.

In addition to the above, another problem that occurs is the "stop" shown in the picture, is attached to the shaft by a "fine toothed " spline which can fail, allowing the shaft to rotate relative to the stop. It is very hard to see this when just looking at it, and when it slips, it still binds on the shaft so you can't easily rotate it by hand, but it will slip again when the force of the kick lever spring slams it against the case bump. If you look at the splines carefully you may see a mis-alignment, but to be sure, you may have to mark the shaft and stop, re-assemble and try it again. A mis-match of your marks will prove it slipped. A replacement of the 2 parts is the surest way to fix it, but I managed to weld the stop on the shaft to fix mine. Also, in the future, do not allow the kick start lever to slam back to the return position when starting.
alnarv

My guess is the stop has let go on the splines. Mine split on my 490 but they used crap semi cast stuff on those & not common for the early stamped out stops to let go. But any--my first guess 'stop' as shown in the bottom in post #2 by JHASSNA.