!!!!how hard did u kick it!!!

2ndtimeround · Jan 6, 2006

U would not ave believed it,just got me a 03/ fe 501 had demo how to start (with the kickstart ) .gets it home thought ill ave a go at starting it! 1kick , 2kicks SNAP! bloody kickstart shaft sheared clean off!! .I was gobsmacked .
any way any body ever replaced one 1-10 how easy dealer said they will do it but cart be arsed trailing it up there as i ave no transport and means some one else running me.
thought ill do myself ?
ant thought or advise

berger · Jan 6, 2006

Well, thats been known to happen from time to time. There is an updated kick start shaft available.
You would have to be capable of removing the clutch cover. Timing and installing the mechanism can be tricky for the novice.
If someone said they would do it for me, I would let them :wink:

LeFrog · Jan 6, 2006

Did you make you you passed TDC with the decomp lever?

I would suspect that if you kicked it hard enough, hitting TDC at mid-kick could do just that.

wildbill · Jan 6, 2006

If you try to kick start it like a 2 stroke then you can have all kinds of trouble. There is a certain way to kickstart a berg--it is all in the follow through not a stomp. Do a search about it and see what you can find out.Hope this helps.

2ndtimeround · Jan 6, 2006

thanks 4 that info i thought it was just my bad luck,as for the de comp it auto matic on reseting the kick start is it not?
because i wasnt using the lever.

Taffy · Jan 6, 2006

if you are a half competent mechanic you can do it but you will have to build the clutch when rebuilding and you'll have to time the two gears on the crank. add to that the actual preloading of the kickstart mechanism which is tricky and you now know it's not a job for the first time mechanic like froggy etc.

if you're on the case then we have a diagram of the timing gears for you in the doc. you'll also find there an explanation of how to fit the kickstart mechanism.

it pays to have a copy of an exploded view of the sidecover as well so you have an idea of how it all re-fits.

ask questions here and if confident in your abilities and our answers why not have a go?

regards

Taffy

sandskipper · Jan 6, 2006

2nd,

I just finished dealing with this same stint of back luck a few months back. Check out the pics of the Sheered kickstart shaft in my gallery. If you have any questions just ask and i will try to help you as much as possible. The newer shaft is made of a much better quality material and looks to fix the issue with this. Dan over at Motoxotica in California had the best price on the part and had it delivered within a few days. The newer shaft was slightly longer than the older shaft but did not cause any problems on installation. I did a little mod on the kickstarter splines to compensate for the extra length and It looks B-E-A-utiful. Hope you sort this out soon and the whole job shouldn't run you more than $200(US). I would say the job is easy to slightly moderate and can be tackled by someone who has basic understanding of mechanics. Give it a shot, it's not hard. There is one thing to remember if you decide to do this yourself, There are two dots on one gear wheel at the crank and one dot on the matting gear just above it, don't go spinning gears and not make sure everything is back in its proper place before reassembly otherwise your timing will be all off. PM me if you have any questions.

Regards,

Taffy · Jan 6, 2006

confirm the year that the shaft was strengthened and i'll update the doc?

just checked the rebuild section and there is everything there he'll need to have a go with confidence.

regards

Taffy

LeFrog · Jan 6, 2006

2ndtimeround said:
thanks 4 that info i thought it was just my bad luck,as for the de comp it auto matic on reseting the kick start is it not?
because i wasnt using the lever.

To get the best kick, one that will provide the most momentum to the engine and the most sparks, you need to start from right after TDC. The hand lever will help you pass TDC, as it is impossible to do it otherwise.

There have been a few threads on that subject lately, including this one.

buckwheat5679 · Jan 6, 2006

I will have to check mine out while the cover is off. :?

berger · Jan 6, 2006

Buckwheat, it's nothing you want to loose any sleep over. It is an item to be replaced as needed.

sandskipper · Jan 7, 2006

Taff,

I inquired about this a few months back when I getting ready to dig into my endeavor. The response I received was from Dale and was such:

The shaft design has remained the same since near inception. The product quality has been random. What you receive is dependant upon when and where it was manufactured. Unfortunately, the only way to know for certain is to inspect it.

Hope this helps.
Dale

This was taken from the second page about half way down... Kickstart shaft thread

The old part # from my '02 bike was (230 097-01)
The new part # I ordered was (230 156-01)

I am not sure what year the new part was introduced but I think it may have been the '03 years and later.... not for certain though. The dimensions are not all the same but I can confirm it will fit into an '02 bike and Dale says they have stayed virtually the same since inception. Hope this help shed some light on the topic.

Regards,

2ndtimeround · Jan 7, 2006

just a quick up date been to D.C.R and he has shown me the 2 diffrent shafts.
the one that breaks has a machined shoulder ahout 3mm wide after the splines & before the shafts full thickness / the replacment is one diametre with just a small taper to the splines , however dave also tells me this new one is heat treated for extra strengh.

and for this to happen is not uknown , but not common place. let u know how i get on after job is done.

thanks again .

wildbill · Jan 13, 2006

LeFrog said:
2ndtimeround said:

thanks 4 that info i thought it was just my bad luck,as for the de comp it auto matic on reseting the kick start is it not?
because i wasnt using the lever.

Click to expand...

To get the best kick, one that will provide the most momentum to the engine and the most sparks, you need to start from right after TDC. The hand lever will help you pass TDC, as it is impossible to do it otherwise.

There have been a few threads on that subject lately, including this one.

The trick is getting the engine to right past TDC. I don`t have a decompression lever or anything on my bike. It can be done just takes a little while longer.

Taffy · Jan 13, 2006

keith

the parts book shows the whole assembly as being updated in '03 and it shows the USA as getting a new kickstart lever as well that year. everyone else got the new KL in '05.

regards

taffy

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