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Kick starter wont return

B

bhbzx7

Joined Mar 2007
55 Posts | 0+
Morganton NC
Ok. I feel like an *****. I changed my clutch cover gasket that was leaking and when I put everything back together did the normal spin it over a few times with the button and and then kick. Started 1st kick. So here i am basting tin the glory of the one kick -kick start and the I noticed the kicker was at the bottom of its stroke. I now have it tore back apart and cant find any loose or disconected parts. I have looked through the doc and cant find anything. Anyone else ever had this happen to them. By the way its a 2001 FX470e.
Thanks for the help.
Heath
 
Did you reset the spring? Usually when the kick start does not recoil, that means the spring is not seating properly. One end of the spring is flat and needs to sit in a hole inside the gear. It is a little bit tricky but not that much.

When you reinstall the clutch, make sure the spring did not come off. Better work with the bike leaning on the right side, gravity will help you keep the kick start gear when it should be. Once the clutch is back on, give the kick start a try by end (remove the spark plug) and see if it works fine. Give one more try before torquing all the bolts around the clutch cover.
 
Actually it is held by the engine case, the spring is held in place by one hole in the case, one hole inside of the gear.

It's a very simple ratchet, but sometimes the spring gets disengaged, or the little keyhole shaped part is pushed out in a manner that prevents it from being stopped. I guess they improved this design because it's mostly with the 01-02 models that people seem to have that problem.
 
Well this is just great... Almost had the kicker working and dropped the little teardrop shaped piece of down the one hole that goes into the tranny. Looks like its going to be a long weekend with no riding for me. All of this for a couple drops of oil in the floor....next time I will just put down a catch pan !!
 
Well, my 2001 leaks oil and I have decided to just ride, clean and top off (if needed), as it may come from so many different things, but mostly warped magnesium covers and also the fact that these bikes tend to overheat.

As for the lost part, I am sorry to hear that. You really want to get that part out of there instead of replacing, because it could wreck havoc.
 
I already have some quality time set aside for a little case splitting fun.
 
I would spend an hour fishing with a magnet before I split the cases. Sweep across the bottom of the transmission through the oil drain plug hole. If you have the little spring for the pawl, and only need to search for the pawl you should at least give it a try. The pawl is heavy enough it may fall to the bottom if you tilt the engine around. I have a Snap-on telescoping extension wand with a small magnet on it. I think you could find something similar. Some light solvent or contact brake cleaner sprayed into the transmission would reduce the oil film so the pawl wouldn't stick to the gears.
 
ok, got it with the magnet.Thanks for the help on that. I think my problem is in the spring itself, does anybody have a pic of the spring itself, I think my spring is sprung. ( no pun intended-well maybe a little pun).
 
No photo, but as I recall it's not a terribly strong spring, maybe a bit more force than one you would find in a ball point pen spring (size is different though). Best to order one from a dealer to be sure it is correct.
 
Talked to Kurt at Bike Barn this am and told to look and see if he had one. If he does I will get him to send it out. Man,I am really ready to go ride....its only supposed to be in the low 70's here tomorrow and I'm stuck with no ride. Neil E. how do you like the 550 ??
Heath
 
Heath, I like the 550 although to me it's just another bike. Some folks here are really wild about their machines but I haven't got there yet. I am still experimenting with jetting, it's the only thing that needs improving. It's a nice machine to work on, fairly easy to get at everything. The one piece steel frame is great, it has allowed me to do a modification (water storage) that would be difficult on any other bike. I have turned it into a good all-round machine for my needs although it looks a bit odd (some pics in my gallery).
 
Re: RE: Kick starter wont return

bhbzx7 said:
Talked to Kurt at Bike Barn this am and told to look and see if he had one. If he does I will get him to send it out. Man,I am really ready to go ride....its only supposed to be in the low 70's here tomorrow and I'm stuck with no ride. Neil E. how do you like the 550 ??
Heath
Click to expand...

Heath,

I checked our stock and do not have that spring you are looking for, however, I have an email into KTM NA (the new distributor for Husaberg) and am hoping to locate the part for you soon. In the meantime, you can check some of the other dealers...I know that Motoxotica stocks a lot of parts or Gary at G&G, but if you still have the spring (its not likely broken) you can view how the spring and pawl, etc all go together by downloading the repair manual on-line at husaberg dot com, then select service then downloads, then you can go through the service manual and see how that system works...also, the trick when pulling the side cover off is placing a thumb over the kickstart shaft to counter the pulling force when lifting the side cover off...this will keep all the springs, cogs, etc in place. Also, notice in the service manual it shows them check the system with the kickstarter before replacing the side cover...this is to make sure it work before putting it all back together. Its a little tricky getting it all in where it needs to be, but its not too bad.

good luck, I will let you know of the parts hopefully next week. Apparently our rep is in Austria buttoning all the parts stuff up with Husaberg/KTM corporate. I should be able to order parts real soon.

Thanks for your patience and sorry for the novel,

Kurt @ Bike Barn MC, LLC
 

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