In my rebuild log over on E2S, I mentioned a problem with swapping out a clutch cover.  I wanted to replace a **** cover with one I had laying around.  Bolted it on and can only get 1/4-1/3 motion on the crank.  There is some kind of interference with the clutch cover near the clutch basket that stops the crank dead.

The factory part numbers are the same for all year of LT500R clutch cover.  The Cometic clutch cover gasket fits both perfectly.  Kicker assemblies are the same for all years.  Clutch baskets are same.  I think the crank balancer shafts were different 87 to 88-90, but its behind the gear and not able to even contact the cover.

The cover that WORKS FINE has a little extra feature on it (see pic), whereas the one that I'm having problems with does not have the feature. 

I've found a couple on eBay that also have the feature, but then found a picture from 2007 of one that doesn't have the feature.

Removing the clutch pressure plate and plates does nothing.  Going to pull the kicker spring, and then kicker gear to see if that's the issue.


I can't be the first one to ever notice this difference or have this issue.

 

Its a girl!  LOL

Thanks for checking.

I would assume that it has to do with the kick starter spring