Kick start play - how much?

[liv2day]

I noticed the kick stater on my '11 ec200 has bit of play (laterally and when engaging). It's not much - probably ~1-2mm on each axis.

Is this normal or should it be completely snug?

Also - does anyone know the torx size to for the bolts?

 

[Jakobi]

A little play is normal. I found it can be reduced by shimming it at the bolt end. A solid o-ring works well.

 

[liv2day]

Thanks Jakobi, going to shim it.

Any idea on torx size?

 

[Jakobi]

I'll check for you tonight if I still have that bolt. I have a feeling I swapped mine out for a normal bolt and a spring washer.

 

[liv2day]

Need some additional help (and apologize in advance for the newb question - this isn't my forte).

First, is there a trick to pull the kick starter off the shaft? I removed the bolts and it slides back and forth, but I cannot get it off.

Second, I do not like the play between the splines on the shaft and the kicker - that's just going to accelerate the wear and I do not see any way to cinch it down to get rid of the slop. Am I missing something on the kicker itself, or does it simply not have a way to adjust?

I'll do some searching to see if there are alternatives, but I want to get this resolved before the shaft gets ground down

 

[Jakobi]

You might need to use a puller of some sort to get it to slide off if its not playing the game. I'll share a tip. Don't sit infront of it and pull it back towards your face

Once its off check the splines on the shaft and the kicker. I found the GG one always felt a bit sloppier than a YZ kicker. They will always have a little slop in/out but should still grab well on the splines. I use the o-ring to reduce the in/out play.

I know there was a batch of bad starter shafts on the 2010 Euro models in Australia. Know of a few of us who had them replaced under warranty. Mine spat all the splines off early in the piece.

 

[liv2day]

'll share a tip. Don't sit infront of it and pull it back towards your face

LOL...I saw the peril in that move last night as it was on the stand and rocking toward me.

They will always have a little slop in/out but should still grab well on the splines. I use the o-ring to reduce the in/out play.

That's my biggest concern - there's enough play before the kicker splines engage the shaft that it will only be a matter of time before it starts stripping/slipping. I'm not overly big on the mechanical stuff, but why isn't there a vice type piece for tightening the kicker to the shaft? Am I missing something, or is the only thing holding the kicker on the shaft the screw going into the end of the shaft?

Maybe I'll take a quick video of the play I'm referring to and post it - could possibly be making a big deal out of nothing?

Thanks in advance for your advice Jakobi - greatly appreciated

 

[Jakobi]

Yepp@! Just held in by the end washer and bolt.

Also, make sure you take the slack up before kicking it over. Stabbing at it is a sure way to cause issues.

 

[Bandit9]

I would get the YZ kick start lever. Once you do that, you don't even think about it anymore.