Many owners of mopeds and scooters with an engine capacity of 150 cubic centimeters are faced with a situation where the electric starter refuses to work at the most inopportune moment. This can happen due to a discharged battery, oxidized contacts, or failure of the electric motor itself. In such cases, the only reliable way to start the engine is a mechanical kickstarter.
Installing this device allows you to gain complete independence from the state of the on-board network and guarantees engine starting even in harsh weather conditions. The modernization process requires accuracy and the availability of certain tools, but is quite accessible to perform in a garage. A properly configured starting mechanism will be your insurance on the road.
Technical compatibility assessment and kit selection
Before you begin, you need to determine whether your engine is factory equipped with a kickstarter. Most Chinese scooters with volume 150 cubes with series engine 157QMJ have a designated place for kick, which is closed with a plug. However, there are engine versions where the mechanism is completely absent, and installation will require replacing the crankcase or installing a special adapter.
Carefully inspect the right side of the engine near the CVT. If you see a round plug covered with bolts, you're in luck - that's the spot for the kickstarter. If it's just a smooth surface, you'll have to look for a universal kit that includes a new housing or adapter that attaches over the existing housing.
When purchasing a set, pay attention to the quality of the gear material. Cheap plastic parts quickly break down under load, especially on powerful motors. Look for kits where the gears are made from metal, and the spring has sufficient rigidity for reliable engagement.
- 🔧 Check that all fasteners are included (bolts, washers, retaining rings).
- ⚙️ Make sure the splines on the kickstarter shaft match the engine primary gear shaft.
- 🛠️ Evaluate the length of the lever - too short will be uncomfortable, too long may hit the footrest or leg.
⚠️ Warning: Do not attempt to install a kickstarter from a 50cc model to a 150cc engine without checking compatibility. Different gear ratios can lead to breakdown of the starting mechanism or the inability to crank the crankshaft with the required force.
Necessary tools and workplace preparation
For high-quality installation, you will need a standard set of tools, which most equipment owners have. Pay special attention to the quality of the keys, since the bolts on scooters often stick due to vibration and dirt. Using a low-quality tool can tear off the edges of the fastener, which will significantly complicate the assembly process.
You will need 8, 10, 12 and 14 millimeter socket wrenches. Be sure to prepare screwdrivers with different tips for removing plastic panels and loosening small screws. A hammer with a rubber tip is also useful for carefully fitting parts without damaging the body.
Don't forget about lubricant. The kickstarter mechanism requires regular maintenance and lubrication of the rubbing surfaces. Use lithium grease or specialized transmission oil. Liquid WD-40 will not work here, as it washes out quickly and does not provide long-term protection against friction.
Organize your work area so that you have easy access to the right side of the engine. If possible, raise the scooter on a stand to allow the rear wheel to rotate freely. This will make it easier to crank the engine when checking the operation of the mechanism after assembly.
- 🔑 A set of heads and collars for unscrewing the crankcase fasteners.
- 🧼 Rags and cleaner to remove old dirt and oil before installation.
- 🔨 Rubber mallet for landing gears without hitting metal.
⚠️ Attention: Before starting work, be sure to remove the negative terminal from the battery to avoid a short circuit if the wires are accidentally touched with a tool.
- Never, only electric starter
- Rarely, in extreme cases
- Often, as the main method
- I always don't use an electric starter.
Step-by-step instructions for dismantling and installation
The installation process begins with carefully removing the engine side cover. You need to unscrew several bolts around the perimeter of the cover. Be careful not to damage the gasket if you plan to reuse it, or prepare a new one to ensure a tight seal.
After removing the cover you will see the variator mechanism. You need to remove the lock washer and the gear itself, which rotates with the shaft. Here it is important to remember or photograph the location of the parts in order to correctly reassemble the unit. Clean the seat from dirt and traces of old grease.
Installing the kickstart lever itself requires precision. Insert the shaft into the hole, making sure that the splines line up with the gear teeth. Rotate the lever by hand to check for smooth operation. It should move with force when pressed down and return to its original position when released.
Secure the lever with a nut or bolt using a lock washer. Make sure the connection is securely fastened and has no play. Any loosening in this assembly will lead to rapid wear and loss of starting efficiency.
- 🔩 Unscrew the bolts securing the right crankcase cover and carefully remove it.
- ⚙️ Remove the input shaft gear and clean the seat.
- 🛠️ Install the kickstarter mechanism, making sure the splines match.
- 🔒 Secure the lever and check its movement.
☑️ Preparation for installation
Common installation errors
One of the most common mistakes is incorrect spring installation. If the spring is skewed or not engaged in the special protrusions, the lever will not return to its original position. They also often forget to lubricate the shaft, which leads to jamming of the mechanism after a few days of operation.
Adjusting spring tension and checking operation
After mechanical installation, the return spring tension must be adjusted. This is a critical stage on which the comfort of use depends. If the spring tension is too loose, the lever will not return to its original position and you will have to manually lift it with your foot. Too much tension will make the pressure too heavy.
To adjust, use a special adjusting bolt or nut on the mechanism. Turn them a few turns, then check the lever travel. It should return smoothly and quickly, without jamming. Make sure that the lever does not touch the motor housing or other elements when pressed.
Make a few test pushes to check how the engagement mechanism works. You should feel a distinct click as the gear engages the engine flywheel. If the stroke is empty, the mechanism is not reaching the engagement point and needs to be moved or adjusted.
After successful adjustment, tighten all fasteners until they stop, but without fanaticism, so as not to strip the threads. Pay special attention to the crankcase cover bolts - they must be tightened evenly so that the gasket does not warp.
- 🔄 Check the return of the lever to its original position.
- 🔊 Hear the characteristic click of the gears engaging.
- 📏 Make sure there is no friction between the lever and the body or footrest.
Before your first trip after installation, make several test runs at idle to ensure the reliability of the mechanism in different modes.
A properly adjusted spring ensures quick return of the lever and reduces the load on the driver's foot when starting a cold engine.
Troubleshooting and maintenance
During operation, the kickstarter mechanism may require attention. The most common problem is the lever sticking or not returning. Most often this is caused by a lack of lubrication or dirt getting inside the mechanism. Disassemble the assembly, clean the parts and apply fresh lubricant.
If the lever turns, but the engine does not turn, the problem may be gear wear. The metal teeth wear down over time and the mechanism begins to slip. In this case, the gears will need to be replaced with new ones. Also check the condition of the spring - it should not be stretched or deformed.
Sometimes the problem lies not in the kickstarter itself, but in the engine. If the compression in the cylinder is too low, it will be very difficult to turn the crankshaft, even with a working mechanism. Check the condition of the piston group and replace the oil if it has lost its properties.
Regular maintenance will extend the life of the mechanism for many years. Once a season, it is recommended to remove the lever and check the condition of the splines and gears. Cleanliness and lubrication are the main allies of reliable operation.
Below is a table of the main problems and ways to solve them:
| Problem | Possible reason | Solution |
|---|---|---|
| Lever does not return | Weak spring tension | Adjust tension or replace spring |
| Grinding is heard | Gear wear | Replace gears with new ones |
| The lever turns idle | The splines are torn off or the mechanism is broken | Replace the shaft or the entire kickstarter mechanism |
| Too tight | Lack of lubrication or dirt | Disassemble, clean and lubricate the assembly |
Final assembly and pre-trip check
After all adjustments and checks, you can begin the final assembly. Reinstall the right crankcase cover, making sure the gasket is level. Tighten the bolts in a crisscross pattern to ensure the cover fits evenly.
Connect the battery and check the operation of the electric starter (if you still have one). Make sure that the installation of the kickstarter does not interfere with the operation of other components. Now try starting the engine using the kickstarter. Press firmly and firmly to overcome the compression.
If the engine starts, let it run for a few minutes. Listen to the sounds of the mechanism - there should be no unnecessary knocks or creaks. Check to see if oil is leaking from under the crankcase cover.
Remember that a kickstarter is not only a backup option, but also a great way to keep your engine in good shape. Regular mechanical starts promote better oil circulation and engine warming up.
Don't forget that on scooters with volume 150 cubes compression can be high, so when starting in cold weather, use suction (if equipped) and warm up the engine before driving.
- ✅ Check the tightness of all crankcase cover bolts.
- ✅ Make sure there are no oil leaks.
- ✅ Test run the engine.
⚠️ Attention: If after installing the kickstarter you notice that the engine starts worse with the electric starter, check whether the new mechanism is touching wiring or other parts when rotating.
Answers to frequently asked questions (FAQ)
Is it possible to install a kickstarter on a scooter that did not have one from the factory?
Yes, this is possible, but it will require replacing the engine crankcase with a kickstarter version or installing a special conversion kit. A simple plug will not help; you need a full-fledged mechanism inside.
How often should the kickstarter mechanism be lubricated?
It is recommended to lubricate once a season or after every winter. If the scooter is used in dusty conditions, the check should be carried out more often, every 2-3 thousand kilometers.
What should I do if the kickstarter lever does not return?
Most likely the problem is with the spring. Try adjusting its tension. If this does not help, the spring may have stretched or broken, then it will need to be replaced with a new one.
Do I need to remove the wheel to install the kickstarter?
Usually no, just remove the right engine cover and the variator. However, some models may require removal of the footrest or crankcase guard to gain easy access to the fasteners.
Does installing a kickstarter affect engine life?
No, if installed and used correctly, the mechanism does not affect the engine life. On the contrary, the ability to crank the engine manually helps avoid starting problems and extend the life of the starter and battery.