Maintenance & Technical > KX500 Original

*@#$%&* kick start lever bustage!

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hughes:
Mine started to over rotate but I found out why. Look at the stop on the kicker itself. There is a steel pin that is pressed in it. This pin was designed to make contact with the stop on the steel knuckle when the kicker is pulled out(ready to start engine mode). The stop on the knuckle just make contact with only half of the steel pin and then it starts to beat into the alumn kicker. I had some work done to may 04 kicker. I had the stop on the knuckle extended so it make more contact with the kicker when it's pulled out. It's hard to explain. My e-mail is not set up at home due to me just moving but a picture would sum up what am trying to say. Also keep that allen bolt tight(the detent screw). mine works loose every ride. Just a little tip for the kicker. I cut a section out of an old tire tube from a kids bike and slide it down over the pivot point of the kicker and safety wire it at the top. It helps keep mud and dust out of the area. I had to remove and clean that after every ride but now it been on their for two rides and zero dirt or mud in that pivot point.

gowen:
Hey, if you can get any pictures sometime that would be awesome. I get tired of buying new $120+ kick starters.

hughes:
Gowen I will try to get some pictures. I am using my work computer right now. I hope my home computer will back up and running this week then I can download a picture.

2001KX5:
I'm buying the 01 kicker assembly - which is the revised one - for $100 canadian.

Huges I know what your saying. I'm go to work on the old one and weld it back up. Then try to find some sore of metal insert that will hold up.  I could prob bring it to a machine shop and its some thing they could do for $50. But I need a fresh one and perhaps now I'll have a backup.

kiwikx500:
isnt the kickstart lever designed to be softer than the shaft on purpose so it wears out first ?

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