• Husqvarna Motorcycles Made In Sweden - About 1988 and older

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85 WR400 kickstart jumping around when running?

NZHusky

NZHusky

Husqvarna
B Class
Hi, I have a 85 Watercooled WR400 and just noticed the kickstart jumping around and coming back and hitting the side cover when running...any ideas why please? kickstart returns backup when started, so I think spring is ok.....
Cheers Phil
 
CAUTION: If you loose the the preload on the kicker shaft when you take the kicker off, you'll most likely have to remove the side cover and start over.

Try this:
You need to unwind the kick starter shaft a couple teeth. Sounds like the kick starter gear is to close to engagement at rest. Are you hearing an unusual clicking sound?
Try pulling the kicker, but grab the splines before you pull off the kicker. Move the kicker 2 teeth clockwise and push the kicker back on. When it's set right you should have about 3/4" between the kicker and the rubber stop on the cover, when the teeth engage to turn the motor over.
 
Have you taken the cover off to see if there are worn parts in that area? My fist guess would be that the needle bearing is kind of destroyed, my second guess is that the face of the hole in the left side main case half that the kick start shaft goes into got chewed up and someone put a washer thicker than they should have in there to make up for that. Just guessing. It is amazing how chewed up some pieces in that area are when you open up an unknown engine. Have you got metal chips in the oil? It is possible to pretty much ruin a whole lot of stuff if that needle bearing destructs and you keep riding just from the hardened bits grinding between the gears and in the bearings.
 
I had the same thing happen. As Fran said its probably lost the needle bearing in the kicker gear. Look at it soon as when mine went it broke the case and the clutch cover.
 
Thats great fellas, thanks for the feedback and movie, Im gonna pull it down this weekend and see whats going on in there. Luckily this started happening on the last race of the day so hopefully not too much damage? This site is so damn helpful.
Cheers
 
Hi Fellas, pulled the kickstart housing off and you guys were spot on, needle bearing shagged!! hopefully i caught it in time. A hell of a lot of shiny bits came out with the oil and one of the photos shows some of the the roller bearings i got with a thin magnet out of the box. Do you think the housing is too damaged? do any of you have a part number for the needle bearing or dimensions please? Also have a look at the water pump impellor!! is there suposed to be a circlip or something holding the impellor on? Lucky I have a new spare kit..

thanks in advance...PhilRIMG0224.JPGRIMG0225.JPGRIMG0227.JPGRIMG0230.JPGRIMG0233.JPGRIMG0228.JPGRIMG0229.JPG
 
Do you think the housing is too damaged?
The waterpump housing doesn't look like the plastic or plastic like material of the ones I am familiar with, both that and the impeller look like trash can or wall hanger material to me.

Pertaining to the hole in the center case I mentioned in an earlier post.

What I have started doing is shimming in that area to make the gear ride as close as possible to the pawl holder piece. I would either make a shim that rides in the worn down area or fill it with epoxey and add say a 10 thousands of an inch thick brass over the whole area because I happen to have some brass like that and it seemed to work for me and so far has been stuck there when the cover comes. off. this may make it more of a pain to install the cover.

do any of you have a part number for the needle bearing or dimensions please?
I would suggest getting a copy of the parts sheet and looking it up. Perhaps this link might start you in that direction, the 1985 sheet is quite readable. https://www.halls-cycles.com/Catalog/Halls-Cycles-Husqvarna.aspx I suspect it is copyright infringment but cd of lots of sheets are (have been in the past?) on ebay most of the time. If you want to get a generic one it goes by id, od, thickness in milimeters. Someone recently bumped one of my earlir posts which shows how I sleeved the gear, that was an hk series but the needle bearing (portion)in it falls apart upon cutting it open and I plan on using a husky part for the needle bearing with the bearing shell machined into the gear. That needle bearing?shell bearing? is the shortest one in the bearing list so that probably tells a tale in itself.

Also have a look at the water pump impellor!! is there suposed to be a circlip or something holding the impellor on?
Yes there is a clip, I see it in the picture/drawing. It has numbers on a similar picture in the parts sheets.
Lucky I have a new spare kit..

Your pawl holder piece is in amazing condition in the way mine usually deform, I can't tell if I see a crack in it or not more towards the center. The bearing surface that the needle bearing rides on in the gear probably is ruined if my parts pile resembles your pieces.
 
Alloy waterpump housing :thumbsup:,nice , never seen one of those , hang on to that.
New impeller and little circlip needed tho.
 
Cheers for the great info!! yeah i have both housings as picture shows and the alloy one looks to have larger internals for greater flow. The circlip must have flown off internally and the impellor was just floating around hence the damage to impellor. The pawl shaft is in good condition as this engine was completely o/hauled about 100 hrs ago and has a 430 Barrel/piston fitted so goes real well. glad i pulled it down early,could be a good save!! Any ideas on Parts supply in Aussie?....not too much around in NZRIMG0236.JPG
 
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