AG 200 Kickstarter spring

[80-85 husky]

Highpowered stuff this .... ive got an AG 200 with a broken kickstarter return spring. is it as easy a fix as slipping the cover off and replacing it?

I assume it should be as simple as that. anyone know any different ..cheers

[smed]

From memory yeah,just remove the clutch cover, AG200's had lots of trouble in that area related to cdi's malfunctioning causing backfiring when starting,also broken decomp cables not being replaced by cockys put too much strain on the kicker assy,yeah I know only 200cc, ya wouldn't reckon would ya ,you might be lucky with just a spring,lots of times it was a broken clutch cover & even worse damaged cases,good luck    

[OverTheHill]

yes just cover off & easy swap, by memory just be careful to locate the spring clamp thing that puts tension on the gear to make it wind out & engage with intermediate gear, also with the return spring you'll have to pull it around a bit to clear the clutch basket to locate it on the peg.
Just this week replaces a broken shaft on an XT125 [with an ag200 shaft--same except has a piece to operate the decomp cable by the looks].
Guy has an XT200 & XT125 on the farm--both with crook ignition--125 ran for 5 then stop--walk home then starts GRRR, suspected source coil which i changed for [another crook one from the wreckers] which then had me chasing the box & top coil--long [few days] story but looks like it had two problems [box plus bottom coil], could tap the box while running & would misfire every time plus with a meter hooked on the stator source coil red & brown i could watch it break circuit after a minute or two--flick flick as it thought about stopping then 'bam' open circuit, that's on ac voltage not resistance 'but with it running'. funny [not] thing is, with my [well damped needle] on my peak meter, open circuit & the needle damping about equaled the motor rolling to a halt but my 'cheap' multi tester on AC with next to no damping showed instant flick of the needle.
Also--XT200 purely turned out to be the pulse [trigger] wire double connector had lost it's hook to hold it engaged & the connection pins had been tweaked & [by accident] found it i touched the wired near the plug she stopped, ended up just tweaking the connections & cable tied the multi plug engaged. Luckily i have a wrecker [dismantler in this pc age] that lets me grab a couple of boxes & stator coils or complete plates which makes life easier. The 125 has a history [$700 at a shop i believe] chasing ignition issues over the last couple of years--kicking back, took teeth off gear behind clutch & intermediate gear, broke kick start shaft, you name it. Luckily i'm retired [just tired!!] so have the time & not gonna give up but i'll 'let ya know if it comes back'. Sory about the essay [story of my week] Cheers [tears]

[Tex]

John, I have a box with a few random AG200 bits in it. Let me if you're after something and I'll take a look.

Tex

[80-85 husky]

cheers guys, ive got a mate with 2 and we are going to make a good one out of them. but I need them both to start and run  as one will ednd up on ebay as a chap runna for some 13 yo kid....

[80-85 husky]

spoiled by huskys, what a complicated little turd this is... the circlip holding the whole shebang has broken (found half of it!) the kicker spring has broken and the alloy pall collet thingy has a crack in it... the clutch cover gasket is $30.00...what a nightmare.
hey Tex, got a clutch cover gasket

cheers

[Tex]

Nah, no gaskets sorry.

Tex

[OverTheHill]

meant to add the other day, that, 'be careful' as there's a couple of washers on the shaft that came off with the cover on mine [xt125] and had bike on it's side so just lucky they didn't drop into the works unaware. One washer has ears to locate it so it turns with the shaft followed by a thin flat washer.
Also [maybe not relevant in your case] the shock on the AG200's get 'all up the creek' with the gas escaping up into the oil. Took the gas piston out of the one i did [xt125] & filled to the top [minus rod displacement] & she's good enough for what it is [no bouncy bouncy]. Bit dangerous to get apart if gas has got up into the oil as will have to carefully drill in the end then possibly drill through the gas piston [which will be forced down to the bottom by gas pressure being on the wrong side of it], this will let oil & gas squirt out under pressure & then you're safe to go further. Ag 200's were very under damped from new, i suppose for a soft ride for the for the farmer plus a great seat. You'll soon know if the shocks stuffed though as she'll just be a 'pogo'. Gosh after reading all that i think i'd just 'buy another shock'!!. One more thought for the day though--rather than pull right apart as i did and if you've managed to drill through the gas piston i think i'd just oil it up with an oil can till it's full [minus rod displacement] and cap the end hole with a screw. Gonna be a slow job as will have to keep continually letting air out from oil can pumping oil in. Special tools required to pull right apart as top seal is a yamaha special two piece flat washer with a tapered center compressed in to tighten around shaft & difficult to release circlip to get apart.--Buy another shock i say & ignore my 'rant'.

[80-85 husky]

yes, she has the boingy boings but I will see how the "other" bike is before openheart surgery.

saw the washers on the microfiche and found them on the floor!

got everything here, just need an hour to reassemble (yep, I will do it 2 or three times till I figure it out!!)

what oil in the engine? ive got some 20 - 40 shell std, that should do it....

[OverTheHill]

Oil--yes 20/40, i just go for the cheapest budget oil at supercheap etc. Just talking 'shocks' again, it might be worth trying turning the shock end for end, so long as the spring doesn't get hung up on anything [airbox etc], i say this because if the gas has got past the piston & gassing up the oil, providing there's still enough oil to cover things now the gas piston will be shot to the bottom then it becomes much like my old 'gas girling shocks [gas oil mix] & they 'have' to run inverted [designed to] otherwise they 'pogo' till half way down. Now the AG'y shock is a long way from being vertical but turned back to front she's a bit 'up hill' under the tank. Only thing is--to do that experiment you'll have to take [guessing] 5mm off each side of the end bush for it to fit into the mount under the tank [going by the xt125 i got involved in]. Cheers. ps, if that doesn't work, return to plan A, just can't remember what it was!!

[80-85 husky]

she is arunner, bit boingy but not too bad, throttle cable has issues and the carb has ahole in the cv diaphragm (my guess ) as it hunts up and down at idle and has a flat spot on throttle opening. but runs sweet for an old clunker

[OverTheHill]

check that the carb manifold hasn't come un-bonded, a lot of those bonded rubber type manifolds gave up eventually. Diaphragm holes a pretty rare but worth checking although would probably just make it run flat--['run well' & smooth but pretty gutless]. Keen to know the outcome. Cheers.

[80-85 husky]

it has gone back to the owner "as is" and he is happy with it. thanks for the advice