2005 EC 250/300 Kicker trouble

[HenrikSchmidt]

The kick starter has been the weak point in my bike. I had the teeth sheer off the actual shaft which were replaced under warranty.

Also saw this on mine, half of the teeth came of with the kickstarter, but just notice it now since It's the first time I have the Kickstart off, I just picked up the bike last summer, with 25hours on it, and put 22hours on it myself, so I don't think there is much luck with warranty on a 6YO bike
Think I have to take it apart to have a good look see, hope not all parts are busted..

 

[Jakobi]

I'm not the only person here who's had that happen either. Its just one of those things that could be better.

I've also had the blt actually snap off inside the shaft ater a fall. Don't even ask me how. It was torqued up feels tight with blue loctite. Since then I run no loctite and a crush/spring washer to keep resistance against the bolt.

Mines also started to bend out of shape against the stops where it engages the kicker. Hopefully the 2012 one is a better design. I've been semi temped to swap mine out with my WR250F.

 

[HenrikSchmidt]

I'm not the only person here who's had that happen either. Its just one of those things that could be better.

Just what i was afraid of..

Does anyone out there have some pics of the wornout sprockets/parts?

If I order new parts, will it be like a lottery? Do I get good "hard parts" that'll last, or the same not so good "soft parts" as the originals?
Or is the replacement parts better quality than the originals??

 

[GMP]

Only problem I have ever had was on my '07 with the original parts, '00, '03, and replacement '07 parts were/are fine. What I heard was that some springs were weak, and prevented positive engagement of the rachet, causing it to slip. When it slips it gets damaged slightly and things get worse until it slips a lot. If you notice it slip replace the spring ASAP and you might be good. IMO its perhaps more than that, some soft parts maybe. If you actually stripped splines from the shaft I would say definetely a problem with the hardness of part. I replaced everything about three years ago and mine is fine now. Also, some guys aggrevate this issue with the way they start the bike, or bikes in general. If you "slap kick" the bike, that is just slam the starter down fast without slowly engaging the rachet first, your asking for trouble.

 

[Jakobi]

Its just the way they are mate. Other bikes over the years have been known for sheering the teeth on the shaft. Keys to making sure it lasts is make sure the kick starter retaining bolt stays fixed. Loose kickstarter will increase load on the teeth. Second is to always push until you feel resistance before kicking. Loads the teeth up and makes sure they bite.

I have no idea about the gears internally though. I've had no issues with them.

 

[HenrikSchmidt]

Thank you GMP for clearing that up for me
thats what I wanna hear, I'm gonna take both bikes apart today. and i'll take a look at the parts, maybe the EC will do with just a new spring (it's not that bad yet), but I think The MC needs a complete assemply with shaft and spockets and the lot.. but it gives me a peace of mind that you did not have any promlems with the replacement parts..

 

[GMP]

It doesn't take much damage or rounding of the rachet to cause a problem. Visually they may look pretty good and still slip, the difference between bad parts and new is suprisingly small. Because of the limited depth of engagement, the very edges of the teeth rounding off is enough. I had photos of mine in the Gallery that were lost, but I may have copies on this PC and will post if I do.

I never had a kicstarter that wasn't a fight to get off, always need a puller, and I anti-seize the splines when new and at every R&R. I can't see that stripping unless there is a faulty part, soft or with a bad taper, that the starter needs to tighten against.

 

[Jakobi]

I never had a kicstarter that wasn't a fight to get off, always need a puller, and I anti-seize the splines when new and at every R&R. I can't see that stripping unless there is a faulty part, soft or with a bad taper, that the starter needs to tighten against.

Might have been a batch. Myself and GG EVO both have 2010 EC300R / Euro Editions. Both had it happen. I think he had to wait several weeks with the part on back order to have his fixed as well. Not sure if thats an indicator that there had been more cases of this in Aus that we weren't aware of.

 

[HenrikSchmidt]

pulled the cover, clutch and gear today, this is what I found..

Teeth ripped of in big chunks, found the rest of them on my oil drain plug. Part made of poor quality cast iron.

Teeth flattend. Part made of good hardend material, failed because of the "bad" cast part.

And The shaft with only half the teeth left, possibly caused by a loose fitting between shaft and kickstarter, the kickstarter is very loose on the shaft, pulled it with ease, by hand..

 

[GMP]

That part looks like crap! Like it came form a Chineese scooter not a GG. Its not cast, but sintered I believe. Mine was much better finished. The rachet teeth on the gear looked just like mine, flattened edges. Now the question is what will the replacement parts look like? Might pay to have them Cryo treated if in doubt.

Never, ever saw a GG kicker shaft do that.

 

[HenrikSchmidt]

I was also amazed by the poor quality..
But looked up the prices and at ?14.95 for the ratchet, maybe the quality is not ment to be better
I would have paid 3x as much for a better quality part..
Think I'm more for making up a new one my self, of some hard tool steel,
but then again, if GMP's parts looked better quality and finish than mine. maybe the replacement's is better??
Hmm.. think I'll order the parts and see how it looks when I get it, but I'm NOT putting a cheap chineese looking thing like that in my gasser again..

 

[GMP]

The rachet has always had a rougher look to it, being a sintered part, but not that rough. I suspect a vendor issue. This is from an '06 correct? Perhaps there was a problem in the '06/'07 timeframe. My newer parts and older parts on my '00 were OK, still in service.

If you can make your own go for it, very impressive.

No pics on this PC, I may have them on my Mac at home, I'll post if so.

 

[HenrikSchmidt]

Here is the one from my '06 EC250, still very rough finish, and the same damage:chipped off teeth.
It has 10 times more hours on it than my MC's, Think the first owner of the MC must have been very hard on the kicker.