Maintenance & Technical > KX500 Original

Kickstarter Issues

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gowen:
I have started to notice my kickstarter is starting to rotate beyond what it is supposed to. I purchased it two years ago and have had no issues with it. Being it used to come out at a perfect 90 degree angle, Which now it is like a 110 angle, so my foot slips off and I can't get a good kick. Is this pretty normal for it to wear this fast? Did I get a defect starter? It is a newer oversized kicker. Anyway, two years ago I paid $86 for a new one, I just paid $135 for a new one yesterday. Talk about a mark up. The actual aluminum kickstarter is what warped.


Is there anything I can do to prevent it if it is destined to happen?

doordie:
gowen,

Drill kick 0.5-0.7mm oversize and put in a 0.5mm steel sleev.

Shims it and it?s like new.

Do this before the hole gets to oval. :wink:

//doordie

hughes:
Mine had the same problem. Just bought a new one for 110.00. What happened to mine was the aluminum kick stater it self was worn where it makes contact with the steel collar that mounts the assembly to the shaft on on the engine(not where the c-clip mounts the kick starter to the steel collar). When you pull the kick start out for starting the kick start and the steel collar make contact(built in kick start stop right behind the tension set screw.). Take a look at yours and see.

afritts4u:
I'm also having kick starter problems. My deal includes some crank oil leeking around the kick pivit area. Only a small amount so I have not fixed it, but it is a little anoying.

 Would apreciate some help knowing how to fix this? The arm itself is slightly bent down, in addition it rotates to far on the pivit itself. Have to use my left foot while standing to the side so I kick into the bike rather than away as you do normaly so my foot does not slip off.

Rick:
The contact point where the aluminum kicker hits the steel pivot causes wear down over time, allowing your kicker to turn past 90 degrees.  Remove the assembly from the bike.  Using a welder (I have used both wire feed and stick), add a little material to the contact point on the steel pivot piece.  If your welding skills are lacking, it is best to disassemble the two parts, but this can be done while assemble as well (if a wire feed is used).  You will add too much material at first, but just use a grinder or dremel to clean up the weld down untilt he kicker is at 90 degrees.  If your aluminum hole is out of round, a bushing is the best fix, but if you just have contact point wear, fire up the welder and save yourself $100.

Rick

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