New Kickstart Cover and Gears- Still Jamming Up  By  brandonk87 (Read 497 times)

Here is a Video:
Alleyoop

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If you put grease anywhere, put it on the main shaft where it goes through the cover, and on the little gear where it sits and turns in its hole.
Do both those pieces fit nice and snug in their holes? Just a little bit of play is enough to make it bind.
Also the small gear is supposed to pop out a little as it turns to engage the front pulley - if it has trouble popping out it will resist the turning motion. A little grease around it's hold down wouldn't hurt either (I forget exactly what it looks like)

I had trouble with mine first because the shaft wasn't all the way through and and I didn't have the clip down far enough to hold it all in where it should be. Then the main spring didn't want to seat, part of it had slipped up and was binding the main gear. I just had to take it back apart and be extra mindful that everything was still all the way down and in place before I went to put the clip on.
It seemed like one of those things that's a lot easier if you have an extra hand, but is doable with two - it's just a little cumbersome.

Also don't forget the new starter bendix support bushing, if you didn't put one in the new CVT cover.