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May 3rd, 2004, 08:56 PM   #1
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Stuck Kickstart Mechanism

I have a 2003 FE501E which I always start with the magic button. On the ride on the weekend I had to zip tie the kickstart in to frame as it was flopping out and snagging my leg. At the time I thought it just wasnt engageing the nylon plug that it rests against but closer inspection after ride shows that is not the problem.

Kickstarter will only move through 1/2 its stroke before locking up. I then must manualy returne kickstarter back up and there is no tension being applied to it by return spring. Bike still starts and turns over easily on button even when kickstarter is locked in 1/2 way position. I have yet to pull clutch/case cover off to inspect but was hopping someone might be able to shed some light.

I recently had clutch off when installing Rekluse autoclutch and at same time filled down burrs on gear selector forks so may have dislodged or upset kickstart mechanizm.

Any advise/thoughts appreciated.

Cheers
Horto
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May 4th, 2004, 07:07 PM   #2
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Hi Horto,
The few times I have had the side cover off I've found you have to be gentle while reassembling. If the kick start shaft slides out of its bearing just a little, the spring will come out of the kick start shaft.
Chances are, that is what has happened to you.
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May 4th, 2004, 07:43 PM   #3
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Twister

Thats basically what happened. Pulled it down last night. The kickstart shaft has pulled out just enough to let the engagment key jump over the engagment sledge, effectivelly letting the spring uwind and causing the engagment key to strike now hit the back of the sledge and prevent further movement. Will need to replace sledge as it was damaged.

Cheers
Horto
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May 4th, 2004, 07:54 PM   #4
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Hopefully they will have one in stock. If not, let me know and I can laser cut another one for you.
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May 4th, 2004, 09:59 PM   #5
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Top Gear have them in stock and are mailing one over to me.

Thanks Anyway.

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Horto
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