Installing the kickstarter shaft of a moped alpha

Any scooter, be it Japanese or Chinese, has the ability to start from an electric starter or a kick starter. If the first one doesn’t work for you, which is a very common problem, kickstarter comes to the rescue. Let's look at the reasons for its breakdowns.

Probably 80 percent of scooter owners use kickstarter. Kick means foot, that is, you start the scooter using your foot, which you need to press on the foot located on the variator. And if you often start the scooter this way, the kickstarter may break. The reason may be either poor quality design (most often in Chinese models), or incorrect and rude attitude. Using my own example, I will say that having a Japanese scooter with a kick starter failure there were no problems, while a Chinese two-seater scooter received two kick starter failures in 1 year. If you simply compare the material of both scooters, then even by touch you can see that on Chinese scooters the variator cover or the kick starter itself has very cheap material.

Kickstarter for mopeds - why is it needed?

Kickstarter for mopeds.
Recommendations for use. Today, most mopeds are equipped with an electric starter due to its simplicity and practicality in operation. The so-called kickstarter is also an integral attribute of every modern moped or motorcycle! And this is not surprising, since in order to start the scooter engine “from the hole” we do not need electricity at all! Thus, companies producing mopeds equip their products with both an electric starter and a “winding foot”, where the electric starter plays the role of the main starter for the power plant, and the foot starter is a secondary one, thereby ensuring a high level of reliability of the motorcycle as a whole!

For example, if your favorite moped has a foot starter, then an unexpectedly dead battery or a malfunction in the electric ignition system of the moped will not leave you without options - you can easily start the engine using the “winding foot”. In addition, if the moped has a classic gearbox, then it is easy to start it “from a pusher” or using an inclined road surface. Well, if your scooter is equipped with a CVT, then starting the engine using this method is almost impossible! Another advantage of the “winding stem” is the simplicity of its design. In case of breakdowns or malfunctions, the kickstarter is relatively easy to repair or replace with a new one. The cost of a new “winding stem” is significantly less than that of an electric starter.

But even such a seemingly ideal spare part still has some shortcomings. The first inconvenience in operating a kickstarter is that when starting, it is imperative to apply maximum physical effort in order to start the scooter’s engine. Also, without some experience in starting a moped engine “from a hole-punch”, it will be difficult for you to cope with the task. Otherwise, you can easily damage the winding stem and cause physical injury. For example, if you start the foot starter incorrectly, it can simply slip off your foot and hit you back very painfully! In order to avoid such troubles, it is imperative to have shoes with non-slip soles.

Video: how to properly assemble the kick starter mechanism on a Viper Activ alpha delta moped

Compressed air

Used to start large diesel engines on diesel locomotives, ships and armored vehicles. Previously, this method was the main one for starting piston engines in aviation. In addition to the usual intake and exhaust valves, additional starting valves are installed in the cylinders. When starting, they open in such an order that the air entering the cylinders through them pushes the pistons and spins the engine. Tanks with compressed air are replenished from the compressor driven by the main engine during its operation.

Instructions for the Alpha 50cc moped and its technical characteristics

Being a typical representative of the Chinese automobile industry, the Alpha 50 cc moped, the instructions for which are given below, is distinguished by its affordable price and excellent driving performance. There are certain shortcomings that inevitably arise in any technology, but this specimen is not a rare guest on the roads of our country. For this reason, familiarization with it and its technical parameters will be very important.

New Alpha moped with an engine capacity of 50 cc

Video: Assembling kickstarter ALPHA, DELTA, SABUR 139FMB

Electric starter

The most convenient way. When starting, the engine is spun by a brushed DC motor powered by a battery (after starting, the battery is recharged by a generator driven by the main engine). But it has one significant drawback: in order to crank the crankshaft of a cold engine, especially in winter, it needs a large starting current, which is supplied by the battery, which rapidly loses maximum current and capacity as the temperature drops. Sometimes, together with the use of too viscous oil, this makes starting in cold weather impossible.

Electric motors of automobile starters have a special design with four brushes, which allows to reduce the rotor resistance, increase the rotor current and the power of the electric motor.

Two ways to start a moped with the ignition key

First, you need to make sure that there is gasoline in the gas tank. Now you need to put the moped on the stand and turn the ignition key to the “on” position (sometimes marked in English with the letters “on”). If everything is done correctly, the panel should light up and the needle on the speedometer will rise and fall. Then fold back the kickstarter foot and press it sharply with your foot, continue until the engine starts. This method of starting a moped always works; for the most part it is used when the battery is very discharged. Also, after winter, the moped needs to be started only with a kickstarter, since the battery could have lost a lot of charge.

Ignition at start

For engines with spark ignition, the problem of powering the ignition system at the time of startup is also relevant. Conventional generators with electromagnets require some time to self-excite, so at the moment of starting the ignition is powered only by the battery. As a result, the IZH and Ural motorcycles do not start when the battery is discharged, although the start is carried out by a kick starter rather than an electric starter. This problem is solved by using a generator with permanent magnets (as on the Minsk and Voskhod motorcycles) or magnetos, which provide current immediately, but such generators have less power. The problem becomes much less severe when using electronic ignition, but it is also unable to operate if the battery is completely discharged. The problem of a completely dead battery is aggravated by the fact that modern generators use excitation windings instead of permanent magnets. This means that even with a rotating motor (for example, a towed car), there will be no spark.

Kickstarter repair on a Chinese scooter with a 157QMJ engine

Typical situation: The winding claw of the Racer Taurus scooter, when pressed, hangs in the pressed position and does not crank the engine. It turns over as if at idle, while some strange sounds are heard from under the variator cover.

The cause of this malfunction lies in the incorrect assembly of the kickstarter mechanism located under the variator cover. Or rather, even in incorrect assembly, and in ignorance of the fact that the variator cover needs to be removed only with the crank removed in advance, leaving the kickstarter shaft in its place.

Beginners usually don’t know this and remove the variator cover along with the crank and shaft, thereby bending the return spring bracket and preventing the correct installation of the shafts. And then they can’t properly assemble the mechanism into a “heap”, so they drive around with the winding claw always not working.

Photo report: Servicing the kickstarter of the Chinese scooter 139QMB (50-80CC)

While the scooter is still new and the factory lubricant remains on the kickstarter parts, the kickstarter works properly: it cranks the engine easily and without slipping, does not creak, and most importantly, after starting it always returns to its place, and does not hang snot.

And as soon as the factory lubricant runs out, the kickstarter parts stick to each other and then problems begin: it creaks, then slips, then does not return to place. I think this situation is familiar to many owners of Chinese scooters, especially scooters equipped with 139QMB series engines.

To avoid this situation, disassemble the kickstarter at least once a season and lubricate its parts. Disassembling and lubricating does not take much time, nothing is particularly difficult there either, so don’t be lazy and service your scooter on time and all technical problems will bypass you.

To disassemble and lubricate the mechanism, you must first remove the variator cover

Then unscrew the bolt on the winding lever, pull it out of the lever and then just remove the lever itself

The shaft that we need is fixed with a retaining ring. We remove the ring with a special puller for retaining rings or we suffer and remove it with the help of a couple of nails and such and such a mother...

There is a thrust washer under the ring - this is a very important device! When disassembling, do not lose it!

Remove the “fungus” from the lid

We take out the shaft with the spring

Before reassembling, carefully wash and lubricate the places where the parts came into contact with the variator cover. You can use any lubricant, but it is better to use copper paste. If you don’t have one, apply regular lithol.

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Apply lubricant to the shaft first

Insert the shaft into the cover, wind the spring

Turn the cover over, place a thrust washer on the shaft and secure the shaft with a locking ring.

Lubricate the “fungus” axis

We move the gear sector of the shaft so that the welded tooth goes behind the “fungus”

We insert the “mushroom” into the lid, making sure that its spring bracket fits between the two ledges

This is where our service ends. All that remains is to put the cover back on and put the winding lever on the shaft.

Let's start repairing the Chinese miracle of technology

The Alpha 72cc moped is one of the most famous representatives among Chinese motorcycles. This moped is perfect for use both in rural areas and on city roads. A durable iron frame, complete absence of plastic parts, large diameter wheels - simply created for domestic roads, the quality of which is far from European level.

If you ride often, the rather high seating position of the ALPHA moped makes it possible to overcome low obstacles. A big advantage when choosing a moped is its low price, which makes the purchase quite affordable. This would be a good choice for a beginner.

There are models with a side trailer. Practical to use in rural areas. A reliable assistant in the household.

Economical, with an engine capacity of 72 cubic meters and air cooling, the Alpha moped is unpretentious. This is an extremely simple transport and servicing it couldn’t be easier! You simply cannot find a simpler engine, and spare parts cheaper than Alfa’s can only be found in a dream.

Anyone can carry out tuning or repairs on an Alpha moped with their own hands.

Before you start disassembling the motor, you should fix it on the center stand and completely remove all the plastic. All power systems should be turned off - tank, carburetor and fuel filter; The oil should also be drained.

The engine should be removed along with the transmission, and the Alpha moped should be repaired on a flat surface.

You can remove the alpha engine according to the following diagram:

remove the muffler and exhaust pipe;
remove the camshaft gear cover;
unscrew all 4 bolts from the cylinder cover;
remove the top cover and cylinder head;
We study the degree of wear of the valves, check how dirty the insides of the system parts are.

Is this your first time repairing an Alpha moped yourself? No problem! A moped is not a hadron collider; nothing has changed in 50 years of moped construction. For convenience, draw a diagram of the location of the parts so that later you can complete the assembly without any problems.

Smartphone to help, take photos of each step so that later you can reassemble in the reverse order without confusion.

If it is necessary to replace the valves, or if there are gaps in the fit, then they need to be removed:

Video: Alpha moped engine. Kickstarter problem

General structure of the scooter

Any scooter owner should know how his vehicle works, because without such knowledge it is not only impossible to find out the cause of the malfunction, but also to eliminate it.

Almost all equipment, no matter in which country or in which factory it was produced, has the same design for a scooter, so after examining and repairing one moped, you can easily troubleshoot any other.

Scooters are rightfully considered one of the most economical and unpretentious means of transportation. Ease of operation, low engine power and amazing maneuverability have made scooters one of the most popular types of equipment.

If we consider the general structure of a scooter, then we can say that this vehicle contains an engine, transmission, suspension, chassis, plastic parts and systems responsible for control . The functions of the main components of mopeds should be considered in detail.

In a scooter engine (the device is often an internal combustion engine - an internal combustion engine), the energy obtained from fuel combustion is converted into mechanical energy, which sets the vehicle in motion.
The main function of the transmission is to transfer torque from the engine to the drive wheel (in the case of scooters, this is the rear wheel). The transmission of most mopeds that were produced from the beginning of 2000 to the present day consists of an automatic variator, clutch, gearbox, and a foot start system.

The diagram shows the general structure of the moped: 1 – front fairing; 2 – steering control panel; 3 – protective steering fairing; 4 – seats for the passenger and driver; 5 – trunk located under the seat; 6 – wing; 7 – side fairing; 8 – rear wheel; 9 – power transmission; 10 – driver’s floor; 11 – suspension; 12 – brake system.

The chassis of the moped includes both wheels, the brake system and the suspension. It is thanks to the suspension, which ensures the connection of the wheels to the frame, that vibrations during driving are dampened, and braking or speeding up are carried out smoothly and softly.

The photo shows the structure of the moped, or rather, the “engine and transmission” unit: 1 – the place where the engine is attached to the frame; 2 – engine cylinder; 3 – the transmission itself, which includes the scooter’s variator device, as well as the clutch; 4 – place to which the shock absorber is attached; 5 – wheel.
Basically, all mopeds have either a two-stroke or four-stroke gasoline engine and, depending on such features, the moped or scooter can be supplemented with various components - for example, an oil pump.
It should be noted that the design of the scooter’s carburetor also refers to the “engine-transmission” unit, although it is not indicated in the photo.

The scooter's control devices include a steering wheel, a series of ignition buttons, turn signals, headlight switches, brake levers and a speed controller.
Plastic cladding refers to all mudguards, fairings, as well as tuning such as spoilers or panels that perform an aesthetic function.

Side mirrors, trunk, saddlebags and other parts that are not included in the basic structure of the scooter are called additional components or equipment.

Despite the fact that many motorcyclists are accustomed to scooters with an automatic centrifugal clutch, on the market you can also find two-wheeled vehicles with a mechanical gear shift system (for example, with a four-speed manual gearbox with an engine capacity of 49.3 cc). Such scooters are considered rare and require great driving skills from drivers.

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Source: https://MotoHolder.ru/poleznoe/ustroystvo-skutera

Engine Features

The engine of the Chinese Alpha moped has characteristic features, thanks to which fans of motorcycle technology prefer this particular model.

Engine capacity - 72 cc. With the right approach, it can be upgraded to 110 cc. Also, if desired, you can increase the speed by 10 kilometers.

The weak point of the engine is the gearbox, which requires close attention and a delicate approach. When repairing the “heart” of a moped, you need to know how to correctly disassemble and reassemble this part of the motorcycle “organism”.

Alpha is equipped with a powerful engine, the circuit of which is complex. If you can’t figure it out on your own, it is recommended to contact an experienced specialist. The price of repairs is quite affordable.

Repair and replacement of scooter kick starter

How does a kick starter work?

The scooter engine can be started in two ways:

using an electric starter;
using a kick starter.

The kick starter is designed to start the scooter engine and serves as an alternative unit in case of problems with the electric starter. Another undeniable advantage of the so-called “winding stem” is the ability to start the engine with a completely discharged battery.

The kick starter system consists of:

drive or ratchet gears;
ratchet washers;
installation bracket;
gear sector or crescent;
return spring;
bushings;
retaining ring;
kick-starter pedals;
pedal mounting bolt.

The operating principle of this system is quite simple. When you press the pedal, the crescent moon rotates and transmits it to the ratchet. This in turn rotates the crankshaft, which ultimately causes the scooter's engine to start. After pressing the starter pedal, release it. After this, it will return to its original position using a return spring.

Caring for the kick starter system during operation

This system, like other components and parts of the scooter, requires constant care and regular technical inspections. During a visual inspection, you should pay attention to the presence of dirt or foreign bodies on the variator cover, as well as its integrity. Preventive measures, such as cleaning and washing the variator cover and kick starter pedal, will extend the life of the parts of this unit.

In addition, during an external inspection, you need to “pump” the starter pedal several times and carefully monitor how quickly it returns to its original position. If it slowly and difficultly rises back, or even hangs down, then it’s time to disassemble this scooter assembly and check its parts. Another reason to look inside the kick starter system will be the inability to start the engine using the pedal and the extraneous sounds that arise under the variator cover.

Before disassembling this unit, you need to clean (or wash) the variator cover and wipe it with a clean rag. After this, unscrew the bolts securing the front and back parts of the cover and carefully remove it. Inside the cover is the kick starter system, which must be disassembled. The ratchet is easily removed if you turn the “winding leg” a little and pull it towards you. It contains a washer and an installation bracket, which should be removed and placed in a container of gasoline to clean them. The ratchet should also be cleaned in the same way. The remaining parts of the system and the interior of the variator cover must be cleaned with gasoline using a brush.

Is Kickstarter a necessity or a relic of the past?

06/13/2013 2821 Articles,

Kickstarter - install the starter lever yourself

Now, finding a model that is equipped with a kickstarter is not so easy, because most manufacturers of enduro motorcycles have simply stopped installing it, putting a regular plug in its place. Of course, if you consider that Japanese and European enduros do not often see off-road conditions, but ride in good conditions, then the manufacturers can be understood. But, in Russian conditions, a kickstarter is simply necessary, because if the electronics or the motorcycle battery fail, then the motorcycle will not be able to start without it.

In appearance, a kickstarter is a bent lever with which you can start the engine. If someone thinks that it can be bought at a low cost, then they are significantly mistaken. Despite the simplicity of the design, a kickstarter can cost an average of 400 euros, depending on the model. Even if you find not a new, but a used kick, it will still cost 200 euros.

Of course, it’s cheaper to buy a kickstarter motorcycle outright, but if you come across an interesting model and it’s in good condition, you can install the kickstarter yourself. Fortunately, most manufacturers, although they do not install them right away, create them in the form of additional equipment.

It is advisable to order the entire set, because the kickstarter is not just one lever. To install the kick, a shaft and an idler gear are also required. If the lever can often be picked up from almost any enduro, then the gear and shaft must be original. The fact that the lever can be replaced is very convenient. In addition to saving money, the motorcyclist also has the opportunity to install a longer kick, if ground clearance allows. In addition, you need to immediately buy a gasket for the crankcase cover, because it will be dismantled. Also, during the installation process you may need various washers, screws and thread sealant.

It is advisable to have a repair manual for this motorcycle model, because the permissible tightening torques are indicated there. Of course, you can do everything by eye, but those with strong hands may overdo it and break the thread. When installing the kickstarter, you can take advantage of the fact that the crankcase cover is removed and check the condition of the clutch. This way, both maintenance and installation of the kickstarter can be carried out at the same time.

The process of breaking in a new engine

In order for the engine to work correctly and for a long time and not have to make repairs, it needs a break-in and a manual book, which you can always download. Correct handling and operation of a new moped is the main condition for using the engine. During the first kilometers of the alpha moped, each part of the engine that works is rubbed against each other, and then the working gap is calibrated. For the new Alpha moped, the run-in mileage will be three thousand kilometers. Do not overload the new motor. This can cause overheating of the pistons group, which will subsequently cause a significant loss of power and many other unnecessary unpleasant moments after break-in, when operation is carried out.

Therefore, for the initial 1200 kilometers, the following should be done: do not exceed speed, work without a break should not exceed one hour, as required by the instructions.

Kickstarter for mopeds - why is it needed?

Kickstarter for mopeds. Recommendations for use.

Today, most mopeds are equipped with an electric starter due to its simplicity and practicality in operation. The so-called kickstarter is also an integral attribute of every modern moped or motorcycle! And this is not surprising, since in order to start the scooter engine “from the hole” we do not need electricity at all! Thus, companies producing mopeds equip their products with both an electric starter and a “winding foot”, where the electric starter plays the role of the main starter for the power plant, and the foot starter is a secondary one, thereby ensuring a high level of reliability of the motorcycle as a whole!

Video: how to properly assemble the kick starter mechanism on a Viper Activ alpha delta moped

Human muscular strength

Used when starting low power engines. On outboard motors and chainsaws, they pull a cable wound around the flywheel or starting drum (“ rope starter”)

");
on motorcycles they use a sharp pressure with the foot on a special lever ( kickstarter
);
on mopeds - rotation of
bicycle-type pedals;
on cars - they turn the crankshaft with the starting (winding) handle
(“crooked starter”). Muscular power is always available and does not depend on battery charge, etc. However, this starting method is not very convenient to use; more often it is used as a backup. On modern cars, as a rule, the use of a “crooked starter” is not provided for at all.

Instructions for the Alpha 50cc moped and its technical characteristics

New Alpha moped with an engine capacity of 50 cc

Video: Assembling kickstarter ALPHA, DELTA, SABUR 139FMB

Two ways to start a moped with the ignition key

Direct Start

The German company BOSCH published the results of experiments to study the possibility of direct (without external cranking) starting a gasoline engine with direct fuel injection. The bottom line is this: in an idle engine with 4 or more cylinders, in one of the cylinders the piston is in the position corresponding to the working stroke. Knowing the position of the crankshaft, you can calculate the volume of air in this cylinder, inject the required dose of fuel there and ignite it with a spark. The piston will begin to move, rotating the crankshaft. Then the process develops like an avalanche and the engine starts. The experiment was considered successful, but, as BOSCH management says, Direct Start is still far from being used on production vehicles.

Kickstarter repair on a Chinese scooter with a 157QMJ engine

Scooter kickstarter repair | Moto blog

The kickstarter is used to start the engine. If your electric starter does not work, this device will come to the rescue. But during operation, the kickstarter may break. This happens due to many factors, for example, most often it breaks due to improper handling. If you hit or sharply press the kickstarter leg, you risk that it will soon break, unable to withstand such a load. Also, the kickstarter breaks due to weak metal. Let's say that the Japanese variator body is much stronger and is made of high-quality metal. Chinese CVTs are much worse, because even by eye you can determine its poor condition. Let's look at the main breakdowns that occur when the kickstarter is handled incorrectly.

Let's start repairing the Chinese miracle of technology

There are models with a side trailer. Practical to use in rural areas. A reliable assistant in the household.

Anyone can carry out tuning or repairs on an Alpha moped with their own hands.

The engine should be removed along with the transmission, and the Alpha moped should be repaired on a flat surface.

You can remove the alpha engine according to the following diagram:

remove the muffler and exhaust pipe;
remove the camshaft gear cover;
unscrew all 4 bolts from the cylinder cover;
remove the top cover and cylinder head;
We study the degree of wear of the valves, check how dirty the insides of the system parts are.

Smartphone to help, take photos of each step so that later you can reassemble in the reverse order without confusion.

If it is necessary to replace the valves, or if there are gaps in the fit, then they need to be removed:

Video: Alpha moped engine. Kickstarter problem

Engine Features

The engine of the Chinese Alpha moped has characteristic features, thanks to which fans of motorcycle technology prefer this particular model.

Engine capacity - 72 cc. With the right approach, it can be upgraded to 110 cc. Also, if desired, you can increase the speed by 10 kilometers.

Repair and replacement of scooter kick starter

How does a kick starter work?

The scooter engine can be started in two ways:

using an electric starter;
using a kick starter.

The kick starter system consists of:

drive or ratchet gears;
ratchet washers;
installation bracket;
gear sector or crescent;
return spring;
bushings;
retaining ring;
kick-starter pedals;
pedal mounting bolt.

Caring for the kick starter system during operation

Why does the kick starter break?

There may be several reasons for the breakdown, because they are the ones that most often happen to most scooter riders.

Kickstarter build . If you decide to change the kick starter or another part, be sure to do it correctly. You will need to assemble the spring, retaining rings and other elements according to the instructions. If you miss something, the kick starter leg simply will not return to the right place (see photo).

Worn teeth . Another common failure. If you press the kick starter foot sharply and often, the teeth connecting the foot and the variator will simply wear off, which threatens the same slippage of the foot. The result will be the inability to start the scooter, so keep an eye on the condition of the teeth.

Broken variator cover . Most often it happens with Chinese scooters, which I myself have witnessed more than once. If you press the leg with great force or sharply, the cheap and low-quality material of the variator cover will simply crack around the leg. Here, repairing a variator on a scooter is unlikely to help, as well as welding. The Chinese variator cover is difficult to weld, the weak material does not allow this, so the only option is to buy a variator cover.

We looked at several reasons why the kick starter breaks down; repairing this rather problematic element may take you a little time, but when you have a similar breakdown on the road, you will have to roll the scooter. There may also be three repair options. In the case of cracked teeth, the only possible solution is either replacement or welding. In the case of replacing a kick starter, you simply need to correctly assemble the entire structure, which will be discussed in another article. And if the variator cover is cracked, all you have to do is replace the cover itself. You can try to weld it, but I’ll tell you right away that there is little chance of fixing it this way.

The process of breaking in a new engine

Therefore, for the initial 1200 kilometers, the following should be done: do not exceed speed, work without a break should not exceed one hour, as required by the instructions.