Any scooter, be it Japanese or Chinese, has the ability to start from an electric starter or a kick starter. If the first one doesn’t work for you, which is a very common problem, kickstarter comes to the rescue. Let's look at the reasons for its breakdowns.
Probably 80 percent of scooter owners use kickstarter. Kick means foot, that is, you start the scooter using your foot, which you need to press on the foot located on the variator. And if you often start the scooter this way, the kickstarter may break. The reason may be either poor quality design (most often in Chinese models), or incorrect and rude attitude. Using my own example, I will say that having a Japanese scooter with a kick starter failure there were no problems, while a Chinese two-seater scooter received two kick starter failures in 1 year. If you simply compare the material of both scooters, then even by touch you can see that on Chinese scooters the variator cover or the kick starter itself has very cheap material.
Why does the kick starter break?
There may be several reasons for the breakdown, because they are the ones that most often happen to most scooter riders.
Kickstarter build . If you decide to change the kick starter or another part, be sure to do it correctly. You will need to assemble the spring, retaining rings and other elements according to the instructions. If you miss something, the kick starter leg simply will not return to the right place (see photo).
Worn teeth . Another common failure. If you press the kick starter foot sharply and often, the teeth connecting the foot and the variator will simply wear off, which threatens the same slippage of the foot. The result will be the inability to start the scooter, so keep an eye on the condition of the teeth.
Broken variator cover . Most often it happens with Chinese scooters, which I myself have witnessed more than once. If you press the leg with great force or sharply, the cheap and low-quality material of the variator cover will simply crack around the leg. Here, repairing a variator on a scooter is unlikely to help, as well as welding. The Chinese variator cover is difficult to weld, the weak material does not allow this, so the only option is to buy a variator cover.
We looked at several reasons why the kick starter breaks down; repairing this rather problematic element may take you a little time, but when you have a similar breakdown on the road, you will have to roll the scooter. There may also be three repair options. In the case of cracked teeth, the only possible solution is either replacement or welding. In the case of replacing a kick starter, you simply need to correctly assemble the entire structure, which will be discussed in another article. And if the variator cover is cracked, all you have to do is replace the cover itself. You can try to weld it, but I’ll tell you right away that there is little chance of fixing it this way.
Compressed air
Used to start large diesel engines on diesel locomotives, ships and armored vehicles. Previously, this method was the main one for starting piston engines in aviation. In addition to the usual intake and exhaust valves, additional starting valves are installed in the cylinders. When starting, they open in such an order that the air entering the cylinders through them pushes the pistons and spins the engine. Tanks with compressed air are replenished from the compressor driven by the main engine during its operation.
Photo report: Servicing the kickstarter of the Chinese scooter 139QMB (50-80CC)
While the scooter is still new and the factory lubricant remains on the kickstarter parts, the kickstarter works properly: it cranks the engine easily and without slipping, does not creak, and most importantly, after starting it always returns to its place, and does not hang snot.
And as soon as the factory lubricant runs out, the kickstarter parts stick to each other and then problems begin: it creaks, then slips, then does not return to place. I think this situation is familiar to many owners of Chinese scooters, especially scooters equipped with 139QMB series engines.
To avoid this situation, disassemble the kickstarter at least once a season and lubricate its parts. Disassembling and lubricating does not take much time, nothing is particularly difficult there either, so don’t be lazy and service your scooter on time and all technical problems will bypass you.
To disassemble and lubricate the mechanism, you must first remove the variator cover
Then unscrew the bolt on the winding lever, pull it out of the lever and then just remove the lever itself
The shaft that we need is fixed with a retaining ring. We remove the ring with a special puller for retaining rings or we suffer and remove it with the help of a couple of nails and such and such a mother...
There is a thrust washer under the ring - this is a very important device! When disassembling, do not lose it!
Remove the “fungus” from the lid
We take out the shaft with the spring
Before reassembling, carefully wash and lubricate the places where the parts came into contact with the variator cover. You can use any lubricant, but it is better to use copper paste. If you don’t have one, apply regular lithol.
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Apply lubricant to the shaft first
Insert the shaft into the cover, wind the spring
Turn the cover over, place a thrust washer on the shaft and secure the shaft with a locking ring.
Lubricate the “fungus” axis
We move the gear sector of the shaft so that the welded tooth goes behind the “fungus”
We insert the “mushroom” into the lid, making sure that its spring bracket fits between the two ledges
This is where our service ends. All that remains is to put the cover back on and put the winding lever on the shaft.
Direct Start
The German company BOSCH published the results of experiments to study the possibility of direct (without external cranking) starting a gasoline engine with direct fuel injection. The bottom line is this: in an idle engine with 4 or more cylinders, in one of the cylinders the piston is in the position corresponding to the working stroke. Knowing the position of the crankshaft, you can calculate the volume of air in this cylinder, inject the required dose of fuel there and ignite it with a spark. The piston will begin to move, rotating the crankshaft. Then the process develops like an avalanche and the engine starts. The experiment was considered successful, but, as BOSCH management says, Direct Start is still far from being used on production vehicles.
Kickstarter repair on a Chinese scooter with a 157QMJ engine
Typical situation: The winding claw of the Racer Taurus scooter, when pressed, hangs in the pressed position and does not crank the engine. It turns over as if at idle, while some strange sounds are heard from under the variator cover.
The cause of this malfunction lies in the incorrect assembly of the kickstarter mechanism located under the variator cover. Or rather, even in incorrect assembly, and in ignorance of the fact that the variator cover needs to be removed only with the crank removed in advance, leaving the kickstarter shaft in its place.
Beginners usually don’t know this and remove the variator cover along with the crank and shaft, thereby bending the return spring bracket and preventing the correct installation of the shafts. And then they can’t properly assemble the mechanism into a “heap”, so they drive around with the winding claw always not working.
We remove the variator cover, unscrew the bolt on the winding claw and remove it from the shaft.
We remove the starter primary shaft from the cover body.
Do not lose the thrust washer of the kickstarter shaft.
We remove the front variator. The work of removing a scooter's variator is described in detail in the article: How to remove a scooter's variator using available tools
We take out the intermediate shaft, as you can see there are completely no traces of lubricant, which is not good. It is imperative to lubricate all rubbing parts.
In order to lubricate the intermediate shaft, it must be disassembled; to do this, remove the pin.
Remove the thrust washer and intermediate shaft gear.
Lubricate the shaft with grease (Litol-24).
We assemble the intermediate shaft in the reverse order. Lubricate the intermediate shaft mounting bracket.
Lubricate the working surface of the shaft.
After completely lubricating the intermediate shaft, set it aside; we won’t need it for now.
And now, pay attention to the fixing bracket of the return spring, it is unbent, and they unbent it unknowingly when they tried to remove the variator cover along with the kickstarter shaft (we do not take our case into account, since it was unbent a long time ago before my intervention).
We remove it and level it.
We install the intermediate shaft into the hole, making sure that the pin on the shaft fits into a special groove.
We make sure that the installation bracket also goes into place.
We look for marks on the intermediate shaft - in our case, these are “arrow” and the letters FT.
We rotate the intermediate shaft gear so that the “arrow” is directed to the crankshaft journal, and the letters FT are directed to the kickstarter shaft (do not get confused).
We also lubricate the bushing.
We are looking for a “brewed tooth” in the kickstarter sector.
With one hand, hold the intermediate shaft gear from mixing, with the other hand insert the kickstarter shaft so that the “welded tooth” comes close to the tooth of the intermediate shaft helical gear, that is, the kickstarter shaft should not rotate clockwise; the “welded tooth” should secure it from turning .
It should turn out like this.
After installing the kickstarter shaft, we put the return spring into place; this is easiest to do with pliers.
After installing the return spring, screw in the pre-aligned fixing bracket.
Before installing the variator cover, do not forget to place the thrust washer on the kickstarter shaft.
Human muscular strength
Used when starting low power engines. On outboard motors and chainsaws, they pull a cable wound around the flywheel or starting drum (“ rope starter”)
");
on motorcycles they use a sharp pressure with the foot on a special lever ( kickstarter
);
on mopeds - rotation of
bicycle-type pedals;
on cars - they turn the crankshaft with the starting (winding) handle
(“crooked starter”). Muscular power is always available and does not depend on battery charge, etc. However, this starting method is not very convenient to use; more often it is used as a backup. On modern cars, as a rule, the use of a “crooked starter” is not provided for at all.
Repairing a kickstarter on a Chinese scooter using improvised means
Mar 14, 2015
It is shown how you can eliminate some kickstarter breakdowns using simple means. more info on the page - valeraprivalov.ru/problemyi-s-kikstarterom-na-skutere-super-sport-acar/
Comments
This is a ratchet from a Suzuki Lets
How did you drill the gear? I tried it manually but there was steel in there
At the end of the season, my kickstarter failed again. The teeth of the crescent were immediately a little scratched and in the end a couple of teeth broke off. then I solved the problem with starting the scooter this way - https://www.youtube.com/watch?v=USmTDyuNiWI
I already had it with a hole. I bought this scooter as a non-running scooter. Kickstarter didn't work. This gear was simply given away and there was no shaft on which it was put on. Perhaps it was pressed onto the shaft, but not much. And of course, drilling is a problem - you need to use a drill with a pobedit tip in a lathe. In order for the gear to spin smoothly on the shaft, everything must be accurate.
I have a problem with the leg, when I start the scooter everything is fine, but after I start it, it’s as if something is rubbing there and there’s a very loud and nasty grinding sound, and it wobbles just like in the video, if you press it to the variator, the noise disappears, but as soon as you let go it's starting, help me, I'm sorry, I'm already for it. I'm scratching my head about the fact that it could be a 4t 50cc engine
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Dude, exactly the same problem. Have you solved it? Also, I put my foot against the variator when I’m driving, the sound disappears.
It’s so difficult for me to say what the problem is with your scooter. you need to remove the cover and where it rubs should be visible. perhaps your version of ". It seems like a crescent moon is rubbing against the ratchet due to a bad washer or bushing. - is correct. Perhaps the crescent axle bushings need to be replaced or there may be some other reason. you have to look visually - after all, I only repair my scooter, but mine didn’t have such a problem.
It’s like a crescent moon is rubbing against the ratchet due to a bad washer or bushing, but I’m not sure whether this is due to this or not
Exotic ways
A car (like a motorcycle) with a manual transmission can be started by towing it with another car (or pushing it with your hands, this is called “push starting”), as well as accelerating it while the gear is engaged on an inclined road.
When the battery is low, you often have to connect to the battery of another car (this is called “lighting”).
In principle, you can start the motor by spinning it with an electric motor powered from an external power supply. The power and operating time of such a network starter are almost unlimited, but it is not possible to connect to the electrical network everywhere.
To start the engine after a short shutdown, a flywheel-drive was proposed: spun by the engine while driving, it then allows you to start the engine without loading the battery.
The engine of a tank or other self-propelled gun can be started with a shot. To do this, the ignition and the corresponding gear are turned on, the tank turret turns in the direction opposite to the intended direction of movement. A shot is fired. The recoil forces the tank to start moving, and therefore the engine starts.
Scooter kickstarter repair
Any scooter, be it Japanese or Chinese, has the ability to start from an electric starter or a kick starter. If the first one doesn’t work for you, which is a very common problem, kickstarter comes to the rescue. Let's look at the reasons for its breakdowns.
Probably 80 percent of scooter owners use kickstarter. Kick means foot, that is, you start the scooter using your foot, which you need to press on the foot located on the variator. And if you often start the scooter this way, the kickstarter may break. The reason may be either poor quality design (most often in Chinese models), or incorrect and rude attitude. Using my own example, I will say that having a Japanese scooter with a kick starter failure there were no problems, while a Chinese two-seater scooter received two kick starter failures in 1 year. If you simply compare the material of both scooters, then even by touch you can see that on Chinese scooters the variator cover or the kick starter itself has very cheap material.
Principle of operation
Inside the body there is a movable cylindrical element called a rotor (in collective farm language - an anchor). An insulated copper wire is wound on the rotor in a strictly defined order, forming several independent coils, circuits, windings, poles, circuits - which, in fact, is the same thing. The ends of each of the coils have their own independent outputs in the form of lamellas (contacts) on the collector.
Inside the main body, two permanent magnets are glued exactly around the rotor. Each of the magnets has a different pole N (north) S (south) in relation to each other. Anyone who went to school will understand...
After you press the start button, the electric current from the battery will begin to pass through the power terminal, the brush and then, passing through the lamellas of one and the rotor windings - it forms a constant magnetic field along the axis of the armature.
