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Honda CB 250 RS project kick start clutch lock problem

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CMXCol:
Hi All

I have a strange problem I have never encountered before.
Having just rebuilt the engine crankcase and top end something does not make sense to me.
Here it is.
Engine turnns on crank with a socket wrench OK.
All gears work neutral can be attained.
When the engine turns the clutch basket turns with it with or wothout the clutch plates inserted.
If I try to turn the engine with the kickstarter it is locked.
If I remove the basket the kick start mechanism/shaft turns fine and turns the drive gear that connects to the oil pump which turns and would if fitted connect to the clutch basket gear.
This also happens if I fit the clutch cover and bearing with the push pin fitted
All clutch plates are within spec thickness.
Seems odd?
Any ideas?
Anyone come across this before?
Is something going wrong in the gear box?

Johnwebley:
I have not worked on these.
But, it's OK with the kick-start cover off?

But locks up when it is refitted?

If this is correct,
I suggest you check the kick-start mechanism and return system



Sent from my SM-A546E using Tapatalk

CMXCol:
No it doesn't work with the cranks case off either.
If I turn the shaft the clutch basket goes on to via splines with its nut it turns freely but it doent turn the engine it just spins.

Laverda Dave:
It sounds like you have disturbed the timing of the kick start on the shaft.

Fit the shaft assembly into the engine casing making sure spring hole at the beginner end faces upwards and the oil hole is visible in its casting recess. Place the return spring over the shaft and engage the inner tang of the spring in the cross drilling in the shaft. Once engaged fit the retaining collar between the spring and the shaft.
Turn the spring free end until you can hook it over the anchor pin. Fit the plain washer against the retaining collar and secure it with a circlip (a new one).
Place the spring seat and spring over the protruding end of the shaft. Fit the decompressor cam ENSURING the punch marks on the cam and shaft are aligned.
If you have removed the clutch make sure you have replaced everything in the correct sequence especially the locking washer that has the word OUTSIDE stamped on it, this goes under the clutch centre but.

Laverda Dave:
That's the inner end NOT the beginner end, that's spell check for you!

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