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September 7th, 2021, 01:03 PM   #1
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Kickstart wont come back up

So I bought my bike without the kickstart arm. The seller said that only thing missing was the arm and everything else would be fine. Try to guess was that the case . When I installed the kickstart arm it was really, REALLY hard to get it moving, even with the decomp lever. Eventually I got it to move (somewhat forced it down) but then it wouldn't come back up. The bike does start with the kickstart and what I've managed to listen it doesn't seem to make any weird sounds while the bike runs and the kickstart arm is down. My only guess is that the kickstart as a whole has been assembled incorrectly or the spring is broken/misplaced

It's 12pm and I'm wondering why I didn't buy a KTM
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September 7th, 2021, 08:10 PM   #2
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Because a KTM isn't a BERG!
Might be worth taking the side cover of and having a look if you haven't already, like you said return spring could be a likely culprit, or not evnough pretension on the kickstarter on assembly? If the kickstarter and side cover isn't installed correctly it can also "lock" the kickstarter I think?
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September 7th, 2021, 11:42 PM   #3
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Originally Posted by juhosirvio View Post
So I bought my bike without the kickstart arm. The seller said that only thing missing was the arm and everything else would be fine. Try to guess was that the case . When I installed the kickstart arm it was really, REALLY hard to get it moving, even with the decomp lever. Eventually I got it to move (somewhat forced it down) but then it wouldn't come back up. The bike does start with the kickstart and what I've managed to listen it doesn't seem to make any weird sounds while the bike runs and the kickstart arm is down. My only guess is that the kickstart as a whole has been assembled incorrectly or the spring is broken/misplaced

It's 12pm and I'm wondering why I didn't buy a KTM
go into FB and Taffmeisters and videos and there is one there of putting the kick start shaft in correctly.

I suggest that if there is a chewed and ficked look to the sledge plate, you put a couple of 1mm washers behind it. to draw the plate out towards YOU.

then fit the sledge plate and the k/s shaft. then the rest.

Taffy
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September 7th, 2021, 11:46 PM   #4
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I took the side cover off and the kickstarter moved quite a bit, like the whole assembly wiggled a good bit. The needle bearing in front of the shaft was out couple millimetres so I pushed it back in. Do I have to take a part the whole clutch side of the engine to re install the kickstarter
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September 8th, 2021, 01:40 AM   #5
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Originally Posted by juhosirvio View Post
I took the side cover off and the kickstarter moved quite a bit, like the whole assembly wiggled a good bit. The needle bearing in front of the shaft was out couple millimetres so I pushed it back in. Do I have to take a part the whole clutch side of the engine to re install the kickstarter
yes you do. remember that the two similar gear to the left are timed to each other via the clutch basket. look for a single dot on one gear and a two dots on the other gear.

Taffy
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September 8th, 2021, 09:53 AM   #6
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Similar inquiry, if my bike starts and runs perfect with electric start but the kicker is stuck and won't move, will any damage occur? That is, do I need to repair it before riding it again? 07 FE450
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September 8th, 2021, 12:34 PM   #7
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If the kickstart is stuck up then it shouldn't cause any damage if you use just the e start
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September 13th, 2021, 10:56 PM   #8
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Taffy, what do you mean by the two gears next to the clutch basket are timed to each other? Do I have to make sure they are in certain position before putting everything back together. There is a chance that the gears have moved a bit so is the engine off time now or what?
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September 14th, 2021, 01:43 AM   #9
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this is what you're looking for.
Attached Thumbnails
Kickstart wont come back up-diagram-gears.jpg  
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September 19th, 2021, 09:02 AM   #10
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I just re assembled the engine and try to guess did i manage to start the bike. I did not. Does the engine for real go off timing when disassembling the cluth? Or do I just suck at kicking the bike? It ran for a brief moment, like a second but then died and that was all I got.
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