How do you fix the pullstart on a 50cc pocket dirt bike?

Answer 1

Hi. Pretty goofy design huh? The problem that occurs with these machines, is that the four toothed "Bendex" pawl, that twists out of the pull starter housing, slips off the two flywheel pawls (i.e. goes off center and binds) when pull starting. This generally causes the starter cord to snap not to mention ripping your fingers off in the process!! I devised a quick fix by using a steel tube that slips snuggly over the flywheel pawls and seats at the base of the flywheel. The tube is just long enough to protrude just above the flywheel pawls (if I recall correctly, the tube was cut to about 17 to 18mm long). The steel tube was then drilled through in situ, with a small drill bit, such that the drill went through the tube and into the flywheel metal cast pawl in two spots per pawl (i.e. two holes per pawl, four holes total). The four holes were then appropriately tapped, and four small machine bolts (I used M3 socket head cap screws) were screwed in, to affectively anchor the steel tube to the flywheel. Now, when the bendex eminates from the starter housing, it is forced to center properly by the retaining tube you just installed, eliminating the bendex slipping off center and binding. Mine works perfectly now. Remember that the tube you installed, will be spinning very quickly, as it is part of the flywheel now, so try to keep your insallation balanced, as well as secure. I used crazy glue on the screw threads to keep them from backing out. Hope this helps. Andrew.