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TafelBerg September 3rd, 2016 08:55 AM

2005 FE450E broken kickstarter mechanism
so i was kickstarting my bike this morning, and right as i gave it a nice big wallop it kicked back hard and now the kick starter is limp and the pawls or ratchet or whatever wont engage! any advice as to my next step? i imagine its going to mean removing the clutch side cover to access the mechanism itself... i could roll start the bike but im concerned theres a little piece of metal floating around in there and i dont want to damage anything...

Jerry450 September 3rd, 2016 08:49 PM

I had the same thing happen to my 2004 fe450.kicked it one day and the kick starter would go down but not engage to turn the engine and would still come back with the spring tension.i removed the clutch cover and clutch to get to the kick start mechanism and the little ratchet tounge was stuck down.i ended up filing a small lead on the edge of it where it was getting caught and filed any burrs of around where it sits in and havnt had an issue since.

BUT before you go taking the cover and clutch and everything off try operating the kickstarter by hand and tap the end of the shaft on the bolt head with a hammer(not to hard as to damage the bolt head) at the same time,as wen i discovered the ratchet was stuck down the slightest bump i gave it was enough to let it spring back up.if i had thought of that before pulling it apart i probably would not of pulled it apart.also if you do pull it apart,remember the timing marks on the primary pinion and idler shaft,the 2 gears to the left of the clutch basket.
Happy travels and hope the easy fix works for you

TafelBerg September 4th, 2016 08:52 AM

cool thanks for the info, ill definitely give that a bash before i go diving in there! funny thing is i can hear the pawl clicking after pushing the kickstarter down and letting it spring back up! also if i operate it by hand it does sometimes engage.

Rainerio September 4th, 2016 09:56 AM

Hit it with a 2x4 in between the hammer the shaft. No damage that way.

Taffy September 5th, 2016 02:48 AM

just open up the side and get a new sledge plate. I would pout two washers behind the sledge plate so that the sledge key can't fall off anymore.


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