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March 11th, 2005, 08:59 AM   #1
Gix
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Kickstart shaft locked up

Hi guys, Just had the clutch side cover off my bike(full cover not inspection plate..04 650 sm) to check the installed gap on my rekluse....once done I put it back together and the kickstart shaft is solid.... I loosened the side case again and the shaft will move.
I removed the case and started again but with the same results... I noticed the case virtually butts up to the starter gear..is there meant to be a shim in between the gear and case ? or am I meant to grease up the shaft? Is the a correct pattern for tightening the cover down ( i do opposites and start at the base). A quick reply would be greatly appreciated as bike is in bits and I'm racing this weekend.
Thanks in advance
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March 11th, 2005, 09:37 AM   #2
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Hi gix
This happened to me on my 05, kick it over a few times it will be fine


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March 11th, 2005, 09:42 AM   #3
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I know this is no help, but i did not have that problem. Was the bike on it's side when you assembled it? The gear must have fallen out or is not meshed properly. When I put it together the cover went on flush. I assembled it with a cordless screwdriver, it only takes a few minutes that way.
Make sure when you get it sorted to run the bike full throttle a few times to make sure the balls dissengauge properly or you will be in for a long day at the track tommorrow.
What spring and ball combination are you running?

Cheers,
Ken
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March 11th, 2005, 09:52 AM   #4
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First off thanks for replying....

I would kick it a few times if I could..but its solid (10st weakling)

As for the rekluse, that isnt the problem as Ive run that already was just making sure the gap was ok(which it is)
The case seem to butt up flush but like I say as soon as I tighten it down the kicker shaft locks up solid...gonna pop my top in a min
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March 11th, 2005, 10:23 AM   #5
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S'ok...Problem solved
will tell you more when Ive been for my chinky
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March 11th, 2005, 12:09 PM   #6
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Ok, from what I can gather when pulling the case off you can slightly pull out the kicker shaft, which puts it off centre.
The only way I could sort it was to refit the case without any bolts, then fit the kickstart and physically writh it around and downwards. The bolts were then fitted but the ones around the shaft were not tightened. I then lifted the bike up and kicked it over a few times to work it in, then tightened the bolts fully.....it now works correctly, and I'm happy........thanks for the input guys
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March 11th, 2005, 01:31 PM   #7
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GIx,
Put the bike on its side,remove the clutch cover,remove the clutch,take out the kick start shaft and you will see that the kick start rachet mechanism is not meshed properly.Mesh it properly and reassemble .
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