worn kickstart

[sterob]

hi..i discovered my newly purchased ec300 08..has a worn kick start the gripping teeth are rounded and gouged so slips on the shaft..i come up with an idea of drilling through the kick start and shaft to fit a bolt..anyone done this fix before..regards steve

 

[pscook]

I would replace the kickstarter before drilling through the shaft and lever. A YZ250 (two stroke) kicker will fit right on, search the forums for the years of compatibility.

 

[Jakobi]

If the teeth on the shaft are truly stripped to the point that the kicker is turning on the shaft then your best bet will be replacing the shaft. They aren't that pricey, and they will fix it properly. A small bolt won't be strong enough to take the forces, and by drilling both parts you will also significantly reduce their strength also.

Are you certain that the kicker is slipping on the shaft and not that the gears at the other end aren't slipping as they engage. It can feel similar, and also a reported issue around that era.

http://www.gasgasrider.org/forum/showthread.php?t=13152&highlight=kick+start+gear

http://www.gasgasrider.org/forum/showthread.php?t=18443&highlight=kick+start+gear

 

[barossi73]

Usually the kicker/gearlever teeth wear much more than the shaft as the shafts are hardened.you would struggle to drill it(have tried a long time ago on a slogged gearlever)
as suggested above-I'd try a new kicker first,replace shaft if that fails