QuestionHello Bill - I have a 1974 XL175 which I disassembled the engine and split the crankcase to repair a jammed kick starter ratchet gear. The kick starter assembly is now functioning properly, but when I reinstalled it into the crankcase, the ratchet gear is not disengaging. Therefore, when turning the crankshaft over, the kick starter gear makes a clicking (ratcheting) noise as the ratchet gear will not separate from it. Also, I cannot reverse the engine direction as the kick starter jambs up and prevents all the gears from moving. Is this OK? I know the kick starter retainer needs to be lined up with the punch mark on the shaft according to my Clymer's repair manual. So at this point, I am not sure what to do next to fix the problem. I see you referred to a Honda technical service bulletin that came out to address this kick starter issue...do you know where I can obtain a copy? Any help would be greatly appreciated, as I am now prevented from putting the engine back together.
AnswerMartin, just taking it apart to unjam the gears isn't the correct fix, as you have found. XL175s are famous for breaking the kickstarter shafts (which are discontinued).
So the answer to your initial question is NO, it isn't okay.
I would inspect the mesh between the pinion and ratchet to see if the teeth are worn down and not meshing properly. The part number for the ratchet has been changed from -000 to -010, which is usually a design change for some kind of improvement. Look at the condition of the idler gear, too.
28211-362-000
PINION, KICK STARTER
28223-362-010
RATCHET
28221-362-010
GEAR
Kickstarter problems plagued the small single cylinder bikes. The 100-125 cc machines from the early 1970s had a complete update, but I don't see that info available for the XLs at the moment. I had to dig into an old answer on a site to see XL174 #2 bulletin mentioned, but can't find it on the web now. Not sure where I found it in the first place, as my 1976 bulletins book doesn't show it. That reply was 8 years ago..!
I see a few new parts available at www.cmsnl.com site, but Euro prices are steep, plus shipping is going to be about $45-50, as well. However, these parts are very scarce. I see one gear on Ebay now. There is an updated part for the 1976-78 models with a 391 code part number, but I don't know if it will retrofit back to your model. The gear must be a nice snug fit and not wobble on the k/s shaft. It looks like they put a hardened steel insert in the 391 gear, based on the photos shown on Ebay auctions. Most of the parts for the 1974 haven't changed for the 1976-78, other than the gear, so that may be a drop-in replacement, but check the dimensions and tooth count before you order/buy one. There are some other 391 parts in the later motors, including the return springs. One spring a 216 code part is actually from a Honda CB160 from the 1960s.
I know the return springs are a big tricky to re-install on the 100-125s, so be sure that yours is put together correctly.
http://forum1.aimoo.com/xlboard/Forum-26430/Tag-175/TopicList.html
That's about all I can say about this problem, right now.
Bill Silver
