Hi all hope somebody can help with this problem as I am starting to get really frustrated. The problem started with the kickstart not engaging, the kickstart would go through the whole stroke without engaging and then return up as it should with the return spring. when the engine was cold i could bring the kickstart down and let go of it and it would snap up and then engage. But with the motor warm I had no luck with that method. I took the hole assembly apart and everything looked mint. Put it back together and it engaged first time took it for a quick spin and it was doing the same thing again. I kept using the snap up technique to get her going when cold then using the button when warm which was working alright until the other day. I pulled down the kickstart as usual let it snap back up but it didn't catch tried it again this time it only returned halfway and was stuck there. I pulled her all apart once again and found the engagement sledge spring was missing and the sledge itself had fallen out and wedged itself between the case and the kickstart shaft causing the problem of the kickstart not returning up. I've searched the forum for similuar problems but have not been able to find any. I'm sorry for for the length of this post but I'm getting desperate for any suggestions and what parts if any should be replaced. thanks in advance.
HELP!!!!! 2003 FS 650 kickstart engagement
- Thread starter big_bore
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- 2003 650 engagement kickstart
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Hello Big Bore:
I'm not a mechanic, but in some opportunitty my bike ( FE 501e '02) broke the kickstartshaft. Also I saw a FE650e'03 with same problem. Please take a look this part. In manual 2003 page 35 pos.14 cod. H230156-01. Check springs too.
Other part you can check is the engagement sledge. Pag 31 pos.20 cod. H230158-01.
I hope I can help you. Good luck and tell us any news.
BR
Morrisberg
I'm not a mechanic, but in some opportunitty my bike ( FE 501e '02) broke the kickstartshaft. Also I saw a FE650e'03 with same problem. Please take a look this part. In manual 2003 page 35 pos.14 cod. H230156-01. Check springs too.
Other part you can check is the engagement sledge. Pag 31 pos.20 cod. H230158-01.
I hope I can help you. Good luck and tell us any news.
BR
Morrisberg
When I bought my bike (2002 FS650E) as "sold as seen" in January this year, the kicker shaft was broken, I bought the parts from DCR in the UK. Cost was about £60 for the shaft and an updated plate. The fitting was easy and I've not had a problem with it since. I think these things can break when you don't kick through fully until the kicker hits the foot peg. If you don't kick through and it fires back then this can fracture the shaft...and damage your leg! I forgot to put the little peg inside the gear when I assembled it and had to take it all apart again.
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where are you from bigbore? (inappropriate name donchya think - or are you from the UK where this form of humour is de riguer?)
there is a guide to putting it all together in the doc probably under 'rebuilding the engine'. the actual main spring is shown in the parts book as the wrong way around so you must get the hook end right in the case where there is a sharp edge inside and you can see through to the gearbox teeth.
something isn't right in the rebuild part by yourself so you need to think afresh and ask afresh to stop this happening again!
regards
Taffy
there is a guide to putting it all together in the doc probably under 'rebuilding the engine'. the actual main spring is shown in the parts book as the wrong way around so you must get the hook end right in the case where there is a sharp edge inside and you can see through to the gearbox teeth.
something isn't right in the rebuild part by yourself so you need to think afresh and ask afresh to stop this happening again!
regards
Taffy
Floppy kickstart syndrome can be overcome thus:
Study the attached piccie - that's how it should look before you slide the gear on with the needle roller. You get to this by offering the bent end of the spring into the hole in the LH crankcase, then offering the kickstart shaft ensuring the spring tang parallel to the shaft engages in the hole as you can see to the left of the splines. Then slide the kick start lever onto the splines, rotate CW and push home the shaft until the key when pushed against it's small spring rests against the plate ramp. Now remove the lever and slide the gear with it's needle roller onto the shaft maintaining axial pressure on the shaft so it doesn't pop off the ramp. Tricky bit is getting the cover on without it popping off the ramp - you'll know it's done that when you hear a mechanical clank and the shaft is floppy with no pre-load. The trick is to keep one hand pushing on the shaft whilst you gently tap on the cover with plastic mallet. When the cover is home, a shoulder on the cover keeps the gear where it should be to stop it popping off.
Study the attached piccie - that's how it should look before you slide the gear on with the needle roller. You get to this by offering the bent end of the spring into the hole in the LH crankcase, then offering the kickstart shaft ensuring the spring tang parallel to the shaft engages in the hole as you can see to the left of the splines. Then slide the kick start lever onto the splines, rotate CW and push home the shaft until the key when pushed against it's small spring rests against the plate ramp. Now remove the lever and slide the gear with it's needle roller onto the shaft maintaining axial pressure on the shaft so it doesn't pop off the ramp. Tricky bit is getting the cover on without it popping off the ramp - you'll know it's done that when you hear a mechanical clank and the shaft is floppy with no pre-load. The trick is to keep one hand pushing on the shaft whilst you gently tap on the cover with plastic mallet. When the cover is home, a shoulder on the cover keeps the gear where it should be to stop it popping off.
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