Shifting and kick start problem

[ariaiam]

I got a 1964 CA77 a few months back, and with some effort it would start, although you had to hold the throttle open, the clutch was stuck, and there was a misfire from one cylinder. While tuning it up I found the cylinder with the misfire had a broken spark plug and the points were off.

Now the real problem started when I tried to start it up again! I was trying to get it going with the kick start, and after a few kick tries the lever started feeling weird and lost resistance. When I tried to check if I had knocked it out of neutral, it wouldn't shift at all.

Well I took both side cases off, and noticed some weird wear on the shift fork from getting rubbed against the chain. While messing with it, the shift barrel seemed only to get stuck and push out the fork when trying to go into third while there was no movement in the transmission. It seemed like it should work fine as long as I didn't try to shift into 3rd while stopped, so after unsticking the clutch I put it all back together. Then I tried to shift between 1st and neutral, and it won't shift again. And when I pull in the clutch, the whole kick start lever falls straight down.

Can someone point me in the right direction?

[G-Man]

The first problem soinds like the kickstarter knuckle is slipping on the spline of the kickstarter shaft. You need to examine thk knuckle for cracks at the end of the slot. These knuckels crack and the slot widens allowing the slippage.

It's hard to see here but there is a crack running from the right hand corner of the slot in the knuckle.




Let's work on that problem first. When you put the right side case back on are you retensioning the kickstart spring?

As for the other problem. Are you rotating the transmission when you are trying to shift?

G

[ariaiam]

I didn't find any cracks in the spline, but I'll check again. I don't think I had the spline rotated correctly when I put the case back on the last time. I reset it and at least it isn't dropping for now. The first time it lost resistance it had about 3 spots in the kick that I still felt some resistance, and then nothing. The same time that happened was when the shifting got messed up.

Most of the time when I have tried shifting the transmission was not moving because I was just shifting between 1st and 2nd to get into neutral. The last time the shift fork popped against the chain and wouldn't shift, I was just trying to get into neutral.