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October 14th, 2017, 08:41 PM   #1
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I Ride: 2007 FS550E Supermotard
Kick starter stuck

Hi all. So I've just put my FS550 back together after installing some Kibblewhite dual valve springs and my kick starter is stuck! I'm a bit baffled by this as I didn't touch it or remove the clutch. Had to remove the whole left side cover to fit my new cam chain but I didn't think this should have interfered with the kicker mechanism as all I did was remove the kick start arm to remove the side cover. So any idea folks?
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October 14th, 2017, 09:03 PM   #2
Kay
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This can happen when you remove the clutch side cover. You need to put pressure on the kickstart shaft while removing the cover if you want to be sure it doesn't jam. What you can also do is putting shims behind the sledge.
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October 14th, 2017, 09:05 PM   #3
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Righto, from more searching it seems like I must had unsettled the kicker mech when removing the side cover, the pro tip is to keep pressure on the kick start spline when pulling the cover off. So I'll need to open it up again and reseat things. My question now thought is: I will need to remove the clutch to do this, right? Do I need to remove any other cogs or is it just the whole clutch basket that needs to come off? Also, what tools do I need to remove the clutch if I have access to a rattle gun?
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October 14th, 2017, 09:10 PM   #4
Kay
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Yes you will have to remove the clutch. At least I've never managed to unjam it with the clutch still on. Just remove the whole kickstart and begin by assembling the spring and the shaft. I find that reinstalling the needle cage last is the easiest way to do it. And yes you should be fine with a rattle gun.
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October 21st, 2017, 07:15 PM   #5
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Thanks for your help on this Kay.
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October 23rd, 2017, 01:19 AM   #6
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you can repair it with just the cover off but it is not a 100 guaranteed result.

just take the kickstart shaft through a normal stroke with the arm fitted. the key will then fall off the end of the sledge. keep pressing down on the end of the shaft REALLY HARD. then very slowly let it return still keeping PRESSURE on the end of the shaft.

if it feels like it is back on the sledge then tap down the shaft one more time with a hammer and try an get that last 1mm out of it.

fit the cover and with just the cover on and bolted up in the local, just try it through a stroke again. it should work but may not. knowingg when the kickstart has come off the end of the sledge plate is difficult but if you do a complete imaginary kickstroke then that should be enough.

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Taffy
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