I’m in the process of putting back together this engine and noticed that the kickstart gear/mechanism makes noise either way you spin.

It’s my understanding that the clutch spins counterclockwise while running.. Why does my kickstarter keep making that clank noise? Is some thing screwed up or am I just not understanding how that shaft is disengaged from spinning while the motor is running.

VIDEO HERE

When the kickstart ratchet mechanism is returned back against the stop it moves away from the gear so for you to be able to revolve the clutch both ways it must be released or it'd pick up the ratchet revolving it backwards [Well, forwards for the clutch which is backwards for the motor] if that makes sense. To put it another way--if the motor was running & ratchet sounding then it can't be fully releasing. So at that point if you stopped the motor & turned the flywheel backwards the ratchet should lock the motor from going back any further.
Ok, i just realized there's sound with the video so i've now shot my theories to bits as it's clicking both ways without locking up in reverse. I give up. Let's know what ya find--please. Can something else click past?, can't think what.

It looks like the kick start shaft is rotating when you spin the clutch... that can't be right.

Maybe the return spring isn't engaged right or something? KIck start shaft should be completely disengaged and not rotating... or maybe my eyes are playing tricks on me... here's the video link again... seeing if it will imbed like it's supposed to.

Yep, as MarkT says [now i play it at half speed] shaft is turning but shouldn't be. but trouble 'is', the spring is internal looking at the parts link. I did one years ago on a "74 MX250. Spring has to be pre-wound half a turn or whatever then tucked behind a tab on the tube to hold it pre-wound Then the shaft engaged & turned a bit more to release from the tab so the stop on the ratchet comes against its final stop position to get the pre-wind under tension. Somewhere in that link to the shaft the case gets involved. Think washer 18 runs against the case on the outside--as in behind what we can see in the video. There will be a dot mark on the shaft & the ratchet to set it right. If the spring is off the pre-load tab then hopefully you can still hook it & bring it around as the slot in the shaft looks long. So hopefully you can hook it in the slot with the ratchet stop out far enough to wind spring tension 'on' then push the shaft through so the ratchet stop takes over. Link below, plus a link to all the parts.

www.partzilla.com/catalog/yamaha/motorcy...tarter-250b-c-400b-c

www.partzilla.com/catalog/yamaha/motorcycle/1976/dt400c

Oh man I hope I do not have to split this thing again..

But I'm almost certain I installed the spring correctly before closing the cases. I do remember doing the pre-wind so that it goes on the inside tab with a little bit of tension. And I remember this cause I was focused on that while setting and sealing the case - i didnt want to knock it off and have it come loose. (unfortunately this was back during the summer, I stepped away from the build for a few months so my memory is from 'months ago' instead of 'days ago' but i'm fairly certain of it.)

Another thing to note, not sure if it would make a difference - the clutch is simply placed on, I did not put the nut on and there is no pressure on it yet. I only placed the clutch on to test everything spinning when I discovered this. Also, I do have washer 18 on the outside of the case under the kickshaft.

My current theory (optimistically) is that i'm not getting this step correctly:Which is referencing this snippit from the manual, correct?

I'll have a chance to mess with it later today or tomorrow so we'll see. If I still can't get it, I will take a better video with more detail.

Yes I recall when I put my 76 DT400 back together that spring looked worrisome that it wouldn’t stay put and critical that it doesn’t move when tapping the cases together. I used a zip tie to hold it in place while the cases went together and cut it off at the end. First attempt at splitting the cases and putting back together was a success. Hope your spring faired as well. Also very helpful to have a service manual. Been three years since I did mine but recall you stick the kickstart in slightly to engage the spring then cock it back a quarter turn and slip it in until it hits home. Release the kicker and should spring up to “ready” position. Hope your click, click, click isn’t the spring going round in the cases.