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IT 490 kick start issue

13 Sep 2019 08:35
webfluid
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IT 490 kick start issue #11
Thanks for all your replies on this.
new spring arrived so fitted it all and it works, BUT
as soon as i wind the spring up and put the outer tang into the case hole and tighten up the case, it appears the spring distorts it’s shape as it is now under tension and the case comes down on the spring and stops it working!
if i loosen the case bolts off and pull the case off the spring it works again.
so inner edge of case around the kick shaft is catching on the spring

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13 Sep 2019 16:08 13 Sep 2019 17:42 by bluntz465.
bluntz465
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IT 490 kick start issue #12
Mic that thrust washer,the 465 had many issues that lead to a redesigned case to stop the breakage in this area.Once the washer thins and the pivot hole enlarges the shaft breaks through.I think 85 and up got the beefed up cases.shame I sold that one and the IT site lost the full rebuild on this.it all began just like yours, the end of the spring broke off in that hole.check the shoulder of the kickshaft hole for wear as well.The early ones may be of magnesium so wear if not maintained.Remember these are RACE bikes and were intended to be torn down and inspected after every race.

1957 Cushman Eagle 1969 Honda 90 ATC 1969 Honda CB250
1973 Yamaha AT3 1974 Kawasaki KH440 1974 Honda XR75
1975 Suzuki TS75 1975 Kawasaki GreenStreak 90 1975 Suzuki GT550
1975 Suzuki TS250 1976 Suzuki GT550 1976 Indian Chief
1976 Yamaha YZ80 1978 Yamaha IT175 1980 Suzuki GS550
1982 Yamaha IT465J

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14 Sep 2019 00:25
RT325
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IT 490 kick start issue #13
Is it possible the plastic spacer has moved & got off the tang that fits in the shaft & pre-loading against the case. When assembled there should be endfloat to feel if you had the shaft around a bit with the lever so its away from the stop--just running clearance, not a lot.

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15 Sep 2019 03:22
bluntz465
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IT 490 kick start issue #14
Mic the plastic spacer as well and the shaft end and its bore hole.That spring may have shortened the plastic once it jumped the end when the washer was left out.

1957 Cushman Eagle 1969 Honda 90 ATC 1969 Honda CB250
1973 Yamaha AT3 1974 Kawasaki KH440 1974 Honda XR75
1975 Suzuki TS75 1975 Kawasaki GreenStreak 90 1975 Suzuki GT550
1975 Suzuki TS250 1976 Suzuki GT550 1976 Indian Chief
1976 Yamaha YZ80 1978 Yamaha IT175 1980 Suzuki GS550
1982 Yamaha IT465J

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15 Sep 2019 06:31 15 Sep 2019 06:32 by webfluid. Reason: spelling
webfluid
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Posts: 176
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IT 490 kick start issue #15
thanks very much bluntz it was the first thing i checked this morning and it was that wretched collar, nylon bush fouling on the spring.
had one last go before removing the clutch basket and it all fell into place.
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