Jerks the starter rope out of my hand!

[rjb]

Has anyone had trouble with their Kawasaki jerking the starter rope out of their hand?
I just replaced both crank seals on my 1979 Trailfire 440, and now when I pull the starter it tries to jerk the starter handle out of my hand on every other pull.
It almost acts like it's trying to run backwards...
The sled has an aftermarket black plastic CDI box installed. Other than that it is 100% original 1500 mile survivor sled.

Thanks for any input

[smitfire]

Did you get the timing set?

[rminier]

Yes...Timing is off....
Did you align the tiny mark on the stator plate with the mark on the crankcase?
Could you have knocked the key out of place when you installed the flywheel? Ask me how I know that can happen>>>

[ljm]

I had one that did that once. Turned out to be the CDI. swapped it for another and it ran great.

[rjb]

Well, it was the flywheel key. I thought I was careful when installing the flywheel, but I still knocked the key out of its slot.
I put it back together and it started right up.
However, the new crank seals didn't fix my problem. The sled starts right up and idles fine but it won't build enough rpms to move. It sounds like it may be running a little rich and the plugs look wet after I tried riding. I swapped out the coil and plugs, but nothing changed. The carb has the stock 230 main jet and the needle is on the 3rd slot like the manual calls for. I also have 140 pounds of compression on both sides. I also checked the enrichment valve and it seems to work fine.
Maybe I need to go over the entire fuel system...

[Matt]

Replace the metering needle & seat in the carb yet? If it's bad, it will let too much fuel in to the carb and start forcing extra fuel through.

[rjb]

Not yet. I have cleaned the carb, but haven't replaced any parts.
I have a rebuild kit with a new needle and seat. Maybe I can clean it out and rebuild it this week.

[rminier]

Glad you found the key...it's easy to knock out of place....I did that on my SkiDoo 9500 this summer!
Things that come to mind that would cause your current issue of not being able to rev up and produce power above idle:
1. Eliminate the possibility that mice built a nest in either the exhaust pipe or the airbox while you were working on the sled.
2. Make sure the impulse hose from the crankcase to the fuel pump is absolutely airtight...no pinholes, cracks, etc.
3. Is the fuel pump working well? Fuel filter in good shape?
4. Is the fuel pick up hose inside the tank (and its fitting on the intake end) in good shape?
5. Make double sure that the enrichener plunger is moving down into the carb body and bottoming out, and leaving a little free play on the cable.
6. Carb jets and passages need to be clean....float setting checked....and as Matt said, your inlet needle and seat may be O.K....but could cause flooding if not.
7. Remove the drive belt, and with the track off of the ground, turn the secondary clutch to make sure there is no binding in the drivetrain from bad bearings, stuck brake pads, etc. etc. It should turn fairly easily.

Hope one of these things is the source of your problem.

[rminier]

[

[rjb]

Thanks everyone for all the advice.
I'm going to start checking things out as I find time this week. I'm starting to get a little frustrated, but I'm sure I will eventually find the problem. Is there an easy way to check the exhaust pipe without cutting it open?

[rminier]

If you suspect there may be some crud in the exhaust pipe, blast from both ends with a garden hose. You will quickly see if anything is in there. Keep blasting until water flows freely and nothing else comes out.
Try to leave the pipe in the sun and the wind to evaporate the water from the inside of the pipe.
You can set the pipe on a furnace register, but that tends to tick off the lady of the house when some oily residue drips on the carpet!
It has been suggested on some other vintage sled sites to throw the pipe on a bonfire for awhile. Apparently this burns a mouse nest or other crud into a powder that can be easily blown out of the pipe.
Frankly, I'm afraid to try that.....I would probably melt some section of the pipe....and the pipe would certainly need a fresh coat of hi temp paint!

[rjb]

Although my repair is not yet complete I wanted to post an update.
I decided to start by cleaning the fuel system (starting with the tank), and I was shocked at what I found. I pulled the tank off and drained it into a clear plastic container. The gas was fresh just the week before and it was black when I poured it out. After it settled in the container there was a thick layer of rust and dirt on the bottom. I tried to post a picture, but the file size is too large.
There were also three check valves laying in the bottom of the tank, and none of them were attached to the fuel line.
Hopefully after cleaning everything, and rebuilding the carb, the sled will finally run well.

[Matt]

You are learning why many of us, when we want to actually ride a sled, go through EVERYTHING. That's the only way to make it reliable.

[JDT]

Amen to that Matt.

[sledhead16]

Piece of mind is worth it I promise.