Hello,
I'm new to this forum and the ATV world so please bare with me.
I am rebuilding a 1985 lt230S. I am trying to put the clutch cover back on and the kick starter gears are dealing me fits. The Clymer manual I have is worthless and gives no instructions as far as how the gears are supposed to mesh/locate when putting clutch cover back on.
Any help would be greatly appreciated!!

 

hey welcome to the forum!

when i installed the clutch side cover on my 230 for the first time, it was a bitch too. and i had no manual haha. the way i ended up figuring it out was by visualizing how the kicker operates, and how far the lever travels, correlating that to the gears, and from there i was able to guesstimate what splines the gear should be on the kicker shaft so that the gear teeth are always engaged no matter what position the kicker is in. the alignment of the gear teeth must be done with the kicker up, as if it was retracted. i wish i could make this sound less confusing and more concise but its all i got. good luck haha! and post pics if you need more help...

 

what luck! i found this old *** video of mine that should help you a bit. haha i didnt even know i had it...

http://www.youtube.com/v/X03QCEdSyzM

 

Thanks alot lt230sman!, you have been most helpful. I believe I have got it back on correctly. There actually are some marks/dots to line up the kick starter lever/ lever shaft/ and gear attached to lever-shaft. But those really don't help much when you go to mesh the two gears when installing the case. So like you said you have to allow the gears to mesh all the way down to the end of the kick starter-levers stroke(down to the foot peg).
Thanks!!

 

yup and also, for future reference, when fitting the cover, if its not going on right, make sure that the rack for the clutch (the little toothed shaft that sticks out of the pressure plate) is turned the right way so that those gears will mesh with the pinion gear inside the cover (on the shaft that the clutch cable goes to). and then while youre installing the cover, feel free to spin the clutch release shaft and wiggle the kicker a little.

good luck!

 

Does anyone have any idea where I can get some oil seals for this machine. All of the oil seals I have seen for sale are for 1987 and up. Are the seals the same for all years.
Any help would be great!!

 

the oil seals should be the same for all years. however, just to be safe, id go to the parts department at you local suzuki place and have them order them for you. the place by me didnt give me any problem, and i have an 86 too. OEM seals are the best by far and for such a cheap but important part i wouldnt take any chances with aftermarket parts...

 

Dude, this actually helped me a little bit all I have is pieces so I don't know what the shaft and gearing looks like coming off of the kick start lever, just a box of parts. Did you take any pictures of the process?