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Enduro Chassis & Body Enduro Frame, Plastic, Brakes, Bars, Controls, wheels, tires, sprockets & gearing.


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Old 01-12-2010, 05:53 PM
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noobi noobi is offline
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Default how do you remove the kickstart

im assuming its supposed to be simple, but it isnt.
i cant get the kickstart pedal base off the shaft, it wont even budge



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Old 01-12-2010, 06:04 PM
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Should be simple. Remove the keeper bolt, then rock the kick lever off it's splines. It may take a few smacks with a dead blow hammer to free any electrolysis. Other options would be to use a puller of some sort. Spray the splines with a good penetrant and let it sit. Heat works good too.
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Old 01-12-2010, 08:13 PM
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The knuckle seats on the taper of the shaft. Even with a clean, antiseized assembly its a bitch sometimes. Get yourself a decent two jaw puller. Thread a short M6 cap screw in the end of the shaft to protect it and give the puller screw something to center on. If its never been off and/or seized some heat may be needed.
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Old 01-14-2010, 08:27 PM
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Quote:
Originally Posted by noobi View Post
im assuming its supposed to be simple, but it isnt.
i cant get the kickstart pedal base off the shaft, it wont even budge

Just use a bit of heat and two hooked levers.
Most bikes viberate,loosen and wear out on the spline or retaining bolt falls out and ks gets lost in the mud.
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Old 09-21-2011, 08:45 PM
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Hoping someone can help with anymore ideas on this one??

I have tried all of the above, heat, levering and wd40 and still no luck.

Is there anything else I can soak it in other than wd40 to try and loosen the teeth??

Frustrated!!!
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Old 09-21-2011, 09:15 PM
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Quote:
Originally Posted by GGEvo View Post
Hoping someone can help with anymore ideas on this one??

I have tried all of the above, heat, levering and wd40 and still no luck.

Is there anything else I can soak it in other than wd40 to try and loosen the teeth??

Frustrated!!!
I had the same problem with a 2001xc300 I used to have. I bought it used and it had a Yamaha kick starter on it. After pulling my hair out I finally discovered that it had a small allen set screw in the knuckle. Once I loosened it the kick starter came right off.
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Old 09-21-2011, 09:17 PM
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spray it with 50/50 atf/acetone mixture.


if you're totally stuck., go to your local decent automotive parts/tools store, and ask for a battery terminal puller. small enough to fit i would guess. i'm betting that will get it off. and it's a handy tool to own. pulls small gears with ease.

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Last edited by stainlesscycle; 09-21-2011 at 09:50 PM.
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Old 09-21-2011, 09:29 PM
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A while ago now, but I used a lot of heat, combined with ENOX? and just tried many different ways of levering it until it broke free.
The splines were all full of junk and crap, cleaned those out and its good now.
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Old 09-21-2011, 10:00 PM
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Quote:
Originally Posted by stainlesscycle View Post
spray it with 50/50 atf/acetone mixture.


if you're totally stuck., go to your local decent automotive parts/tools store, and ask for a battery terminal puller. small enough to fit i would guess. i'm betting that will get it off. and it's a handy tool to own. pulls small gears with ease.

that is exactly what i pulled mine off with..workd great
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Old 09-22-2011, 12:37 AM
lankydoug lankydoug is offline
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Mine has tried to jump off and get lost in the woods twice already. I have put locktite on both bolts and still have had to buy the bolts and check balls on two occasions. Be glad that yours stays on.
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