Fixed it. The spring was not the problem. It's apparently just a matter of correct assembly. I made some pics. If I have time I'll explain the essentials.

Everything on pictures is OK. Problem is the shaft and return string wrong assembled. You have to seat the return spring properly during gearbox case assembly. This spring keeps the shaft at angle where some part of the case keeps the flip closed when kick start lever is in top up position.

[quote="serpico-3"]Hergot, 7 let jsem se učil angličtinu a člověk si písemně nepokecá a nepokecá... :)[/quote]
no vidis, ja asi jen 2 roky na skole, a pak spoustu propařenejch hodin u pc :)

muzes to trochu lip zformulovat, co presne kam, jako ze ma byt ten kolicek otocenej o 180 stp ?
something about the correct settings of the shaft into the cover, getting more exact info ...

Tak mu přece napište , že má špatně nastavenou (otočenou)tu startovací hřídel . Musí mu dosedat na ten kolík v bloku (víku)převodovky. I do not speak English :(

Hergot, 7 let jsem se učil angličtinu a člověk si písemně nepokecá a nepokecá... :)

Good idea! Will check it out.

i would just use a spring from a pen to test it. it has to have correct length and sufficient power to rise the flip. check if the sound is gone if you remove the spring

I just took the kickstarter gear out and disassembled it. See pics below. Indeed: spring and pin that pushes the block outside, this is also how it should be according the parts catalog (see other pics).

I agree with your statements about a very easy spring (it is not an easy spring) but I find it strange that there is a spring in it that is too strong.... The bike is not mine and hasn't driven for a few years but it does not look to me that someone "improved this".... mystery... what would you do? Take the whole spring out and see?!

Thanks, Stephan.

[attachment=3]Pic1.JPG[/attachment][attachment=2]Pic2.JPG[/attachment][attachment=1]Parts.JPG[/attachment][attachment=0]Parts2.JPG[/attachment]

if you should have any spring there, it would definitively create that sound.i think it should be freely movable or with a very easy spring. when correctly working, the flip would be not in contact with teeth during normal run. when you want to start it needs to be extended and it should be working on gravity or motion of the shaft. consult with parts catalog

Hi there yes indeed. I think it's indeed related to the "flip" on the shaft but I checked that and it could move. It did not go smooth though... do you (or anyone else) actually know how the "flip" should function? Like you said simply opening and closing freely? It looked to me there was some spring inside pushing it outside...on the spot where there's the red arrow...

[attachment=0]Capture3.JPG[/attachment]

the issue would be probably with alignment of this gear vs kick shaft. the flip on the shaft schould be closing freely. in that case there shouldnt be any sound. if it is stuck then it will do that sound. the sound it is definitely not ok, you are correct :) anything creating sound is usually signed by wear, so you should be able to see where it comes from.

Dobry den!

Pardon, nemluvim Cesky... :-/. Ale mam "problem".. ;-)

I've replaced bearings in my URAL650 gearbox, assembled it and all seems to work ok. However it makes a constant "kickstarter-clicking/rattling-noise".

Please take 1,5 min to watch the YouTube video: https://www.youtube.com/watch?v=-SlVLwtsg_U

I think this is not normal, and if it is how will it go away?

The sound comes from the kickstarter gear (displayed below) and is generated by the small iron assembly on the kick starter shaft (see pic below).

[attachment=1]Capture.JPG[/attachment]
[attachment=0]Capture2.JPG[/attachment]

Your advice / opinion is much appreciated!

Thanks, Stephan.