This site may earn a commission from merchant affiliate links, including eBay, Amazon, and others.

Help with removing kickstart and gear shift

Joined Apr 2012
30 Posts | 0+
West Texas
so i am needing to get my kick-start off and gear shifter to get the cover off. But i can not.i think that when the po stalled then engine and tried to restart it, something happened to the kick-start. it got all chewed up. anyone have any help for me? I dont want to break anything. here is some pics....

IMAG0200.jpg

IMAG0201.jpg

IMAG0202.jpg

IMAG0203.jpg
 
Lean the bike onto the right side and spray some penetrating oil onto the splines. Let it set overnight. Gently/evenly pry the levers off with a ssuitable pry bar. Try not to bugger any seals.
 
Hi, if its a bad as it looks go with the penetrating oil ,a bit of gentle heat [heat gun is ideal] and a small gear puller should do the trick and minimise any damage too cases and levers...........colin
 
I always use some oil or wd40, some little taps with a rubber hammer en then gently pulling at the kickstart or gear lever. They're indeed a little annoying in removing, but just keep trying, they will come off!
 
so i have been trying to remove these for the last 2 weeks. I have used PB Blaster and let it sit, and nothing. Tried the heat, and nothing, gear puller, and cant get a good hold on them. I have to ask, if i just cut them off, where can i get replacements? i have checked ebay, and they dont have any for my year, but what else will work? Its not being a nice bike at the time...... :angry:
 
what is this bike again? on my older berg the gear selector is held onto the splined shaft with a pinch bolt, if you remove the pinch bolt you could open the hole by tapping a chisel into the slot where the bolt goes through to open the circle more, i cant tell for sure what i am looking at in the picture.... my gear selector is steel not aluminum like yours appears to be? aluminum would be prone to breaking before bending but still may work, with the kickshaft....there is almost no room there to get a good puller on unfortunaly and it is aluminum which corrodes to everything it touches, have you tried giving it some real heat to the spline/shaft seat area with a torch not a heat gun? this will easily melt the o-ring seal if your not careful but you have nothing to loose if you are out of options, generally soaking with penetrant and 2 good small/midsize prybars would work. you may be able to get a puller on it or pry on it better from both sides if you move the lever halfway through the kick. can you attach a slide hammer to it somehow? maybe the good style 2 rounded jaw power steering pump pulley for an auto would work? or modify the jaws of a regular 2-3 jaw puller to get behind it with it in the half kick position? risky and will surely mar something up, but if you can get a chisel in between the case half and the kick start shaft, or one on each side of shaft in the same way??? can you tap the kickshaft in more toward the engine with a small ballpeen just to get it broke free from the shaft? ok im out of quick thinking idears....i think if you cut it off they are all the same from 89-96 probably even up to at least 1999 but i do not really know for sure so dont take my word for it......if i think of something else ill post back, there is always a way, just dont get mad and never say never! :cheers: easier said than done i know :?
 
Bergini said:
what is this bike again? on my older berg the gear selector is held onto the splined shaft with a pinch bolt, if you remove the pinch bolt you could open the hole by tapping a chisel into the slot where the bolt goes through to open the circle more, i cant tell for sure what i am looking at in the picture.... my gear selector is steel not aluminum like yours appears to be? aluminum would be prone to breaking before bending but still may work, with the kickshaft....there is almost no room there to get a good puller on unfortunaly and it is aluminum which corrodes to everything it touches, have you tried giving it some real heat to the spline/shaft seat area with a torch not a heat gun? this will easily melt the o-ring seal if your not careful but you have nothing to loose if you are out of options, generally soaking with penetrant and 2 good small/midsize prybars would work. you may be able to get a puller on it or pry on it better from both sides if you move the lever halfway through the kick. can you attach a slide hammer to it somehow? maybe the good style 2 rounded jaw power steering pump pulley for an auto would work? or modify the jaws of a regular 2-3 jaw puller to get behind it with it in the half kick position? risky and will surely mar something up, but if you can get a chisel in between the case half and the kick start shaft, or one on each side of shaft in the same way??? can you tap the kickshaft in more toward the engine with a small ballpeen just to get it broke free from the shaft? ok im out of quick thinking idears....i think if you cut it off they are all the same from 89-96 probably even up to at least 1999 but i do not really know for sure so dont take my word for it......if i think of something else ill post back, there is always a way, just dont get mad and never say never! :cheers: easier said than done i know :?

Bergini,
its a 02 400. I was just frustrated with it yesterday. I dont know what else to do. The gear lever does have a pinch bolt and i did take it out. i didnt want to mess up the seals so i didnt want to use too much heat. We will see what i can do. Thanks for the info.
 
Just wanting to update this thread. Got them both off with the help from my brother-in-law. Used about a 4 foot breaker bar that he has. The timing gear has to be cut off, just cut one of the links. Here is some pics. Will have to split the case cause don't know why it was frozen.

IMAG0209.jpg


IMAG0210.jpg


IMAG0211.jpg


IMAG0207.jpg


IMAG0208.jpg


IMAG0212.jpg
 

Register CTA

Register on Husaberg Forum! This sidebar will go away, and you will see fewer ads.

Recent Discussions

Recent Discussions