Broke kick start shaft

yes this does happen. i haven't had to fix it myself, tho i have had experience pulling apart and refitting a working unit. it is a fiddly job first time round!!!

usually hear of it on the bigger bore bikes. i also beleive it is more common if you follow through with your kick too hard, and put pressure back on the mechanism as the kickstarter hits the footpeg.

the workshop manual that you can download here will guide you through the job, but try doing a search on here as there are some more useful tips available in other posts on this topic. like i said, it is a bit fiddly on reassembly.

Have Fun
Jeff

Also check to see if your auto decompression device is working properly.

be positive you might have had to split the cases, head and barrel off etc with any other catastrophe! :twisted:

regards

Taffy

EuroEnduro said:

I was riding in Idaho City this weekend when I broke my kick start lever shaft on my 03 501. I was wondering if anybody has ran into this problem and is it a complicated fix?

Thanks EuroEnduro

Click to expand...

A revised shaft has been implemented.

Dale

This shaft could be improved with some surface hadening via induction of teh splines, much the same as some automotive or industrial applications that use splines at the end of a shaft. Perhaps Dale can tell by looking at the fracture surface if the spline region was surface hardened. My guess from Dales pic is that they do not get hardened. They may even be softer than they should be to expedite machining. BD

When you replace the shaft be sure and check for anything that might have worked loose. That is what happened to mine although I didn`t break a shaft I can see that it could bind it enough to cause it to break. Good luck.

EuroEnduro said:

Dale, could you fill me in on the newer shaft. Harder steel I hope. Ive had about 12 bikes and this is the first time I have ever broke a kick start shaft.

Thanks EuroEnduro

Click to expand...

The left shaft is that of the new design. Note How the splines terminate. In addition the threaded bore no longer runs the entire length of the spline and the shaft appears to be that of a different temper and / or material.

Hope this helps.
Sincerely,
Dale

HELP!! NEED SOME HELP!!

I've just read your article, but am interested in howto put the kickstart shaft mechanism back together. I have looked and dwnloaded the workshop manual but the pictures in it aen't of that good a quality. So I have trouble seeing what it looks like when it says 'refer to diagram to see how spring is input into shaft' & 'rotate shaft with kickstart allowing it to fit as per diagram' or similar.

I only noticed this after the side casing was back on - naturally!

Can anybody help???

Ta

Rosco

rosco

why haven't you spotted this in the owners doc. we put together this document to stop us 'legends' from getting irritable due to answering the same questions all the time... say no more?

now because you think i'm a w......r for pointing this out and in a mood of reconciliation BEFORE you get pissed with me i will tell you how to do it!

you have a hook end to the spring and that is fed down into the gearbox hole and hooks around the case where it sharpens to a wedge of aluminium.

the other end has an obvious hole in the kickstart mechanism-out it in there. the keyhole shaped ratcheting piece of metal needs to be swung clockwise over the stopping plate until it is at the left end of the said plate.

now press it all down and let go. the keyhole piece will whip anti-clockwise and stop against the right-hand end of the plate which you'll note is raised slightly.

regards

Taffy

Hi EuroEnduro
Same thing, same bike ...
Mine was caused by valves not set correctly causing a kick back. I would advise you set up your valves once you've replaced your shaft. Personally I find the valves prefer to be tighter rather than slacker.... same bike n all.

Regards
Ady

Taffy said:

rosco

why haven't you spotted this in the owners doc. we put together this document to stop us 'legends' from getting irritable due to answering the same questions all the time... say no more?

now because you think i'm a w......r for pointing this out and in a mood of reconciliation BEFORE you get pissed with me i will tell you how to do it!

you have a hook end to the spring and that is fed down into the gearbox hole and hooks around the case where it sharpens to a wedge of aluminium.

the other end has an obvious hole in the kickstart mechanism-out it in there. the keyhole shaped ratcheting piece of metal needs to be swung clockwise over the stopping plate until it is at the left end of the said plate.

now press it all down and let go. the keyhole piece will whip anti-clockwise and stop against the right-hand end of the plate which you'll note is raised slightly.

regards

Taffy

Click to expand...

Taffy,

Sorry I didn't have the time to wade through all the archives on the site, but thanks for getting back to me.

I was doing it the way you suggested after all, it's just that for some reason the the engagement key doesn't stop on the swedge as it should. So this allows the shaft to turn back more (due to the retained tension in the spring) and lock itself off. Not allowing the kickstart to move at all. There is some wear indicated on the swedge so a replacement will be order today.

I have another query for you also. I've not checked the archives yet so don't get p!$$ed.

I have sheared the inner free wheel gear a couple of times now. The first time was whilst opening the throttle during kick starting. Not a good move on my part I know. Lesson learned.

I also did it again this weekend. Due to my kickstart shaft not being in use, I re-installed the starter motor. Due to me stripping off the wiring harness and battery etc, the means of starting the bike was by a jump starter battery. With the jump unit in 12v mode, it turned the engine over, however not fast enough to make it spark. With 24v going through it the engine fired up almost immediately. After numerous starts, about approx 10, the same gear stripped again.

Is this a problem with the 02 bike and would a later part be better, same goes for the kickstart swedge. Or is it just me being impatient to get racing??

Thanks again,

Rosco

P.S. Remember: It us newbies and less experienced boyo's that turns you guys into legends!!

hi rosco

not really sure what you mean by the 'inner freewheel gear'? is this the gear above the crank gear that is driven by the clutch basket gear or are you on about the plastic gear behind the clutch assembly?

are you on about one of the starter gears?

whatever i can say right now that i've not heard of any such problem on any of the models although alas everything seems to have happened at least once on this site!

common fault? no way.

look in my gallery and you'll see that i have some photos of a modified stop plate in the kickstart. the idea is that instead of the kickstart engaging after you have booted it the first 5"; instead i have got it to engage after about 2" and it makes a helluva difference.

why? coz when my bike was standard it wouldn't start. as soon as i moved the kickstart around one spline and loaded the spring it started everytime. with my mod though you don't have to load the spring etc.

sounds like you have yet to get the mechanical knack of knowing when to wait for things to be done correctly and in the right order. it's also known as patience....!

regards

Taffy

Well crap!! Yesterday me and some of my buddies are out running the gauntlet when I overshot my turn and brake hard to whip a turn.... bike stalls as I plow threw the sand trying to stop. Pull the kicker out and snap.... the kickstarter with the splined end of the shaft fall into the wash!!!! Now im stuck in the dessert about 10miles from the truck in 105 degree heat. I was able to get the bike out of the wash and back onto some hard pack but almost have heat exhaustion at this point. Buddies come back looking for me and we get the bike clutch started and get it back to the truck without problem but now looks as EuroEnduro and I are in the same position..... Guys, where can I pick me up one of these newer upgraded(splines) parts that Dale speaks of? Is that the only difference or is the steel hardened? My pats manual shows part# 230 097-01 but this is the stock part, what am I looking for? This will be the first time I have ever pulled the side cover, is there anything else I should do while I have it apart?

Regards,

Same part number / revised part. View the pictures and description earlier in this thread regarding old versus new.

Best Regards,
Dale

Dale,

I just hung up the phone with Dan from Motoxotica in regards to the kick start shaft on my '02 FC550. He does have a kick start shaft in stock and tells me he can ship it to me. I enquired on revision of the part and it is for late 90's-2002 husabergs. The shaft talked about in this thread is off a '03. Is the '03 the shaft I want and compatable with my '02 as this is the revised part and ordering a earlier part# will just get me older marginal shaft like the one I have in my bike now? Dan tells me he has two '03 parts on order and could have one to me by next week if this is indeed the one I should get...... Any help would be appreciated.

Regards,