how do you remove the kickstart

[noobi]

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

 

[roostafish]

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.

 

[GMP]

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.

 

[gasmonkey]

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.

 

[GGEvo]

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!!!

 

[gasser]

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.

 

[stainlesscycle]

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.

 

[noobi]

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.

 

[jhendr3702]

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

 

[lankydoug]

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.

 

[GGEvo]

Thanks all.

Will give those suggestions a try!!

 

[GGEvo]

Not a great outcome. Took it down to a mate who owns a bike shop and the spline was all rounded. We eventually removed the kick starter but I will need a new spline shaft and kick starter

Reckons he has never seen a spline like it before!!

Oh well a call to the dealer tomorrow to order a new one.

 

[stainlesscycle]

i have an kickstart shaft in excellent condition on ebay now. ebay #370544869394 - significantly cheaper than new....

 

[Jakobi]

Not a great outcome. Took it down to a mate who owns a bike shop and the spline was all rounded. We eventually removed the kick starter but I will need a new spline shaft and kick starter

Reckons he has never seen a spline like it before!!

Oh well a call to the dealer tomorrow to order a new one.

This is exactly why I had the dealer remove my RHS cover.. to replace the shaft! I wasn't fully rounded by had multiple sheered teeth.. Warranted by GG..