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Kiick starter shaft binding when I reinstall the side cover.

Joined Dec 2006
160 Posts | 0+
Los Alamos, NM
I am trying to put my 04 Fe650 back together.

I was warned about the kick starter shaft. So when I took the bike apart. I made sure that the shaft did not pull out. Or so I thought.

When I put the side cover back on the shaft stays free until the very end when I torque the side cover bolts. Then it binds.

I have removed the cover and installed the kick starter lever. Then I tried to reseat the shaft. I just can't seem to get it to re seat. The shaft really doesn't allow for me to move it around a whole lot.

My questions are.
How far does the shaft have to pop out before it looses it's positioning?
Do I need to pull the clutch basked to look inside to get the indexing right? I have worked this hard by hand I can't seem to get a feel for what is wrong.
 
How far does the shaft have to pop out before it looses it's positioning
not as far as you'd think. read the section in the doc about positioning the shaft w/o the gear and try it again
 
hit it!

tap it down, it has come out a bit so put a kickstart arm on it, check it functions how you expect and then tap the shaft back down and in.

regards

Taffy
 

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