Snapped kick start shaft

[dANbOT]

I had already replaced my GG kicker for a YZ250 unit, but in the middle of some e-start issues my kick start shaft snapped at the start of the splined section. I'm guessing this is a no-crossover part?

I'm taking another stab at getting my e-start working so I can ride without worry until I get some parts.

 

[dANbOT]

Found a used shaft on ebay from a 2013.

I researched a little and the same kick start shaft is used back to at least 2005(as far as i looked back) on the 200/250/300

 

[motopsycho87]

Good info, thanks!

 

[CombatYoga]

Same exact thing happened to me. Bike was 9 months old approx and GasGas warrantied it. It's easy to replace. Just look carefully at the spring that goes into the kickstart shaft so you put it back together correctly. I knocked a spring or some piece off of a shift fork and had to scratch my head for a while before I got it back together. Now I take pictures
with my phone as I disassemble.

Good luck!

 

[mcnut]

I have the parts you need. See my ad in Parts.

 

[dANbOT]

Thanks for the offer mcnut, but I had already ordered from ebay before you posted.

The shaft I bought was from a 2013 part-out. As a complete unit... it was a direct bolt in but a few details were slightly different on the other parts of the unit. It appeared that the shaft has never been updated but some of the extras had been between 13 and 14. No problem, I just installed the complete unit and it works great. I also fixed my e-start so the kicker is likely never to be used again anyways... good to know its there for backup starting though.
As I was assembling, I found what may have been the source of the break. The small silver spacer between the kick start lever, and the side cover was on backwards from the factory which left some missing support on the shaft (in my mind). The taper on the spacer is supposed to go inwards and match to a taper section on the shaft... mine had been backwards which left the kicker out further on the shaft.

 

[Andrea#92]

Same thing also happened to me...on a 2015 ec 300 with 60 hours
Unfortunately it happened to me in a very bad moment...just before the sixth checkpoint in the red bull hare scramble
Under a climb I tried to turn on the bike and I saw the kickstart fall down
I haven't the electric starter so I had to leave the race with still 1 hour and half available....

Now I mounted the older version (which is all full)

 

[vlatertje]

kickstarter shaft

Same thing also happened to me...on a 2015 ec 300 with 60 hours
Unfortunately it happened to me in a very bad moment...just before the sixth checkpoint in the red bull hare scramble
Under a climb I tried to turn on the bike and I saw the kickstart fall down
I haven't the electric starter so I had to leave the race with still 1 hour and half available....

Now I mounted the older version (which is all full)

Did you mount an older model shaft wich isn't hollow? what part is it?

mine snapped off to after a couple of hours.

 

[dANbOT]

Here's a link to one of my other threads when I was suffering with broken kick shafts. I ended up ordering used ebay shafts from 2000 and 2002 EC's which are both much beefier than the newer style. I can't recall which of the two I installed, but it has been problem free ever since.
In the other thread you can see the difference in the pics. Hope this helps!

http://www.gasgasrider.org/forum/showthread.php?t=20097

 

[Dingo_ed]

I just finished the the repair too. Used a 2001 EC250 shaft and gears on my 2017 EC300. I did notice the ratchet paw on the 2017 was shorter than the one on the 2001 unit. Didn't think of it at the time, but maybe I should have taken a few mm's off the 2001.

I think the shorter 2017 paw gets more throw being it allows the spring more tension when the units set. Bike starts one to two kicks when warm, getting that first kicks a bit different. Not as much drive when kicking, yet the spring is in the correct timing location and lever sits correct angle.

Plus I had to file the kick lever splines because they got buggered up by the broken shaft. So the fit on the 2001 shaft was very tight, had to tap it on with the hammer, and wished I'd remembered to put anti-seize on first.

Now to pull the case will be a chore, the kick lever will not budge now. Don't know how I'll pull the kick lever next time I need to. Maybe get a three arm puller and grind it down thin enough to get behind the lever?

Has anyone had issues pulling the stuck levers? This one is on for good. I filed the splines and it fit, but it was super tight and I only have about 2mm of space from the case. On some bikes you can do the kick start lever retaining screw trick, but these do not have the long hood coming over the retaining screw when folded open.

 

[john r b]

kick shaft

Dingo. lay the bike on its side, slightly heat the shaft then stab it with a candle
the wax will find its way in helping with removal.

 

[Dingo_ed]

Great I'll give that a go. Then I'll file the splines a tad more and use anti-seize on reinstall.

I finished the job late Saturday night and after I set the lever on, I knew I should've gone to bed and rethought it in the morning.