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Author Topic: Kickstart Pawl Replacement  (Read 1727 times)

Bankerdanny

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Kickstart Pawl Replacement
« on: February 05, 2008, 09:59:54 PM »
So last Fall I ordered the sintered kickstart pawl as my kickstart seems to be slipping (It's not the lever, I checked that first).

The text says "installs in about 30-minutes" OK, but how?

I have the spiral bound service manual, but frankly it is so limited in its coverage that it's like the Readers Digest condensed version of a repair manual.

I have followed the link provided by several people to the Enfield Workshop manual at Tripod, but it's not really any more helpful. Nice expanded view, but that really isn't a substitute for a good step-by-step description.

Can anybody describe the install, or better yet, point me to a more comprehensive repair manual?

 I am really quite adept at this kind of stuff, but I don't have a garage to work in, so don't have the luxury of figuring it out on my own, I need to get in and get out in a day, can't leave the tranny opened up over night.

Thanks
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Kevin Mahoney

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Re: Kickstart Pawl Replacement
« Reply #1 on: February 05, 2008, 10:53:50 PM »
4 speed or 5 speed?

Bankerdanny

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Re: Kickstart Pawl Replacement
« Reply #2 on: February 05, 2008, 11:02:56 PM »
'02 500Es 4-speed.

I just ordered the Snidal CD-ROM, so maybe that will help.

Thanks Kevin.

Are you guys at the Chicago motorcycle show this weekend?
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Kevin Mahoney

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Re: Kickstart Pawl Replacement
« Reply #3 on: February 05, 2008, 11:25:30 PM »
1. Remove the outer transmission cover
2. Remove the shift mechanism paying strict attention to the order in which parts are removed
3. Remove inner-transmission cover. Note that the shaft which protrudes frmo the cover has a LEFT HAND thread.
4. When you remove the outer transmission cover, look on the inside and you will see the pawl.
5. Pull it out with a pliers making sure not to lose the plunger and spring.
6. Dig out any of the old grease which may have hardened
7. Re-assemble
8. Re-adjust the shift ratchet mechanism

Bankerdanny

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Re: Kickstart Pawl Replacement
« Reply #4 on: March 11, 2008, 12:30:09 AM »
bump
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