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May 25th, 2007, 05:56 AM   #1
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stuck on kick starter- Wish MotoXotica luck

poor MotoXotica is trying to replace my water pump seals, say they can't get the kick starter off my bike. This is the kinda dirt bike mechanic stuff I dread. I hope they get my bike fixed and back together today so I can ride it this weekend. wish em luck.

story is 140 hrs on the bike and my water pump seals are gone, leaking coolant thru the weep hole. seems they needed to take off the clutch cover and kick starter to get to the back seal?

anyone else had to do it this way and found their kick starter stuck on the shaft. They have tried pulling it, heating it , soaking it in solvent, etc. tried for 2 hours yesterday to remove the damn thing, no luck yet.
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May 25th, 2007, 07:08 AM   #2
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That's a tough one bigbob.
Maybe try leaving the bike on its side overnight with a penetrating lube on the shaft. A pneumatic hammer with a flat bit may loosen it with vibration. I've had good luck this.

I know it's too late now, but I feel the dealer should take the time to dab some anti-seize on the kicker shaft, shifter shaft, swing arm pivot bolt etc. before letting a bike roll out the door. These items have a huge potential to become future "stuck" problems. Really too bad this isn't part of the assembly process back at the factory.

Good luck!

log
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May 25th, 2007, 07:42 AM   #3
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Log has some good suggestions.

I personnally would start with removing the bolt first
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May 25th, 2007, 07:54 AM   #4
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Originally Posted by berger
Log has some good suggestions.

I personnally would start with removing the bolt first
hehehe you suck!

possible if you can find a small enough gear puller and the jaws can wrap around the lever, might be a bit awkward but it might work...
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May 25th, 2007, 07:55 AM   #5
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thanks,

dan hang that bike from the ceiling from its kick starter and bang on it like a pinata is my idea.
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May 25th, 2007, 09:59 AM   #6
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what is ironic here is a couplke weeks ago a customer called me and said he could not get the lever off his 1997 to replace the clutch and wanted advice.i said i had never heard of this before.he was starting to price out kickstart levers and shft.ouch!he did go so far as hanging the bike from his rafters while trying to heat up the kick start knuckle with a blow torch.would have maed a good photo.i am thinking about dynamite right now!dan
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May 25th, 2007, 10:15 AM   #7
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Not sure if it will work but you could try using a freon or other compressed gas and shock cool the shaft then heat the starter - combined it might be enough to free it up.

At least the steel shaft and the aluminum starter should respond differently to the heat cool cycles and this will help free it up.

Freon should produce -50C

Electrical guys used to use it for trouble intermitent circuits

Mark
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May 25th, 2007, 10:58 AM   #8
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Here's my two cents;

There is a penetrating oil known as KROIL http://www.kanolabs.com/ , as per their web page, this oil will "creep" into area's with only one millionth of an inch of space. I personally reccomend the non aerosol version.

I have used this oil in the past with a great degree of success for loosening stuck parts. I also use it on my weapons for cleaning and keeping them from rusting while in storage, it does not evaporate.

It will just take a degree of patience and I'm sure this stuff will work. My suggestion would be to lay the bike on it's side and fill the depression between the shaft and kick knuckle with Kroil and just let it sit. Then use some very light mechanical force, IE tap on both sides of the knuckle simultaneously with two hammers, opposing force. Perhaps even heat the knuckle with a torch as well. You also might try slipping the kicker shaft back on and use it to pry up and down on GENTLY, this will apply axial force. After soaking one could also just re-install the kick shaft and try kicking the bike over as well, this will apply radial force.

Repeat this procedure as neccessary. Be patient it may take a couple of days to have success. Remember, it took a lot more than a couple of days for this thing to weld itself together.

Hope this helps,
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May 25th, 2007, 11:59 AM   #9
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I had the same problem with my 400 and what we did was to weld flat bar on end to
kick starter and then we used a regular puller and pulled it off as I recall it needed
some heat to come loose, then it is just to grind off the flat bar
from then it has been standard operating procedure to put anti seize on the spline's
when I get a new bike and no problem removing kickstarter

good luck VIKING
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May 25th, 2007, 12:41 PM   #10
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thanks for the advice guys.

hey dan, I have an idea patch up that 450e, sell it to the next guy, then give me a special bigbob, your best customer and loyal advertizer, a retail price trade in deal on one of those 06 Fe550's you have sitting there. I owe 5000 to the bank on my Fe450e I want to ride this weekend, My finace is bummed out now.
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