Copyright © 2020 Dirt Rider. Nothing is working. Whether screws available these days are JIS or Phillips is anyone's guess, but I would guess Phillips, not JIS, the differences being largely esoteric. It will slide outward on the splines about 1/16 of an inch and will go no further. The puller will pull straight up, where the other methods will tend to cock the part, causing it to bind. I'd most likely saturate it with that PB Blaster and then loosen/remove everything attached to and/or around the kicker apparatus and then hold your breath and pull straightforward. I like to think "It shouldn't be this hard" when I'm working on stuff then I try to think like the guys who made the item I'm working on and try to imagine what they'd do and then suddenly I break something. As others have mentioned, it takes some time to get use to the Ural layout. Loading... Unsubscribe from souperdoo? by brianural » Wed May 02, 2018 9:25 pm, Post A Bonnier Corporation Company. Fortunately, they weren't serious and it should function just fine. I have always been able to install the kicker without taking the clutch cover off, by removing the kick return rubber stopper. by jleewebb » Fri Oct 16, 2015 11:39 am, Post I have to do the same thing! Spray a little water on as you drill.This is also easier what of removing the kick starter as you can punch the roll pin out and replace it afterwards. The stock KDX kickstart is a piece of crap. by Lmo » Wed May 02, 2018 5:29 pm, Post Fixing a Cracked Motorcycle Engine Case / TS185 - Duration: 10:00. Using the 3-inch puller, I hosed the shaft and lever splines down with penetrant, pulled a bit, backed off, re-centered the tool and pulled it again.

The moral of the story? The picture/tutorial given in the FAQ section is on the money -- other than not covering those of us with K/S on our bikes.

Either it'll work or it won't.

RichardMott Posts: 552 Joined: Mon Jul 22, 2013 6:36 am Location: King of Prussia, Pa. Re: correct kick start lever installation. When i want to shift up by heel, everytime i hit to kickstart lever. I know it is very light alloy and subject to cracking. Then continue to unscrew the bolt; you'll notice the flange on most bikes' start lever overlaps the bolt. The dealer wanted $140 to R&R the water pump (and replace it with new). Then continue to unscrew the bolt; you'll notice the flange on most bikes' start lever overlaps the bolt. http://www.craftsman.com/shc/s/p_10155_12602_00946905000P?vName=Tools+%26+Equipment&cName=Hand+Tools&keyword=puller. The 3-jaw puller was not ideal. I use needle rollers about the width of the lever. Top. I am having some serious issues removing either the quadrant (ratchet) or the kick starter lever and then pushing the whole thing through. In theory, you should be able to pull that center-bolt out and slide the lever off its splines. How did it turn out? I would get about a milimeter movement each time, and ultimately, the thing popped off the splines. The bolt acts as a puller and should significantly loosen the starter lever so you can pull it off by hand.

by RichardMott » Mon Oct 12, 2015 7:15 am, Post

It does require drilling in the end of the shaft between the shaft and lever (round key type) I find a couple of 3 or 4 mm pins usually does the job. . 2005 Gear-Up, Mr. Nat_ural 108,000+ Kilometers and counting. I got the job done for about $35 -- which includes the $16 spent on buying the puller set. No big deal, I thought. 29:56 .

250 four-stroke motocross bike comparison. Whether it falls off when you really need it or is just stuck on the shaft when you want to take it off, kickstarters can be a hassle. Sure you can start the bike with your hand, but the lever is far too long, and gives you so much leverage, that it ends up wearing out the boss very quickly. Looks like a small jawed gear puller would do it -- but I don't have such a tool.

All the best, RPG, Less fatiguing to use your toe to push down to upshift- no shin splints. See, wasn't that easy? The shaft should press out of the quadrant. We'll try to help. by viclioce » Sat Oct 17, 2015 7:25 pm, Users browsing this forum: No registered users and 8 guests, Powered by phpBB® Forum Software © phpBB Limited, The main Page for the Hodaka Club Discussion Group, I just bought my first Hodaka, Dirt Squirt model 01. I use a small two jaw puller when they are stuck. Next stop: Tool store for a small gear puller. It has to come straight off the shaft.. if you do not pull it straight off it will bind. The original screws, so I hear, were JIS. by Bullfrog » Fri Oct 16, 2015 10:05 pm, Post KTM MC 250 77 Husky CR 360 77, Husky 82 420 Auto Bitsa XR 200 project. Don't flame, hate, spam. jo360 - justintendo replied above that the kick start spring and mechanism will unwind if I take the lever off without removing the case. Wanted - 1978 TS185 frame or frame&motor. ; D Victor, Re: correct kick start lever installation. Same one I recommend for the CS sprocket. I'll just remove the bolt holding the k/s lever on its splined shaft and pull the K/S lever. Offset is about 2" back and starts so angled part begins where lever sticks out from frame. Both are so on there it's like they're welded. It is important to keep an open mind.

I figured I could use them for other projects as well as this immediate need. The sacrificial bolt is a good concept. Better control in getting the right amount of "stomp" to shift up. First loosen the bolt holding the kickstarter, but don't remove it. I ended up buying a 3-puller set of 3-jaw pullers (3", 4", and 8" -- 16 bucks on sale) from Harbor Freight. A KX 125 lever can be retrofitted instead, and provides a few advantages. - Duration: 3:26. By The Ural's made Maine a much bigger state. You dont use the roll pins as the spline or drill them in from side you drill all the way thou the kick stater and the shaft one 5mm normaly works. All rights reserved. Reproduction in whole or in part without permission is prohibited.

It simply will not move past that 1/16 of an inch. PO removed kick starter for another bike. 2020 Glen Helen 2 EnduroCross Race Report, 2020 Glen Helen 1 EnduroCross Race Report, 2020 Fox Raceway National Motocross 250 Class Race Report, 2020 Fox Raceway National Motocross 450 Class Race Report, 2020 Off-Road Bikes—Jordan Graham’s Ducati Scrambler Desert Sled. Thanks to all who offered their advice on this topic! A 2-jaw puller would have been easier to center and would have likely made the job considerably faster, but the 3-jaw unit got the job done, ultimately. How to install the kick start gears on a 125-150cc GY6 four-stroke engine, common in scooters, ATVs, buggies, and karts. I'm interested in these for my 09 SM. The good thing about telling the truth is that you don't have to remember what you said. Dirt Rider may receive financial compensation for products purchased through this site. Single special bolt in the center, clamps in on. First loosen the bolt holding the kickstarter, but don't remove it.

The shaft should press out of the quadrant. I will likely go shopping this evening for a small jawed gear puller.

The bike is completely stock and original and runs great. Have you done it yet? fotosaurus, May 22, 2014 #9. stormer254 Husqvarna AA Class . That still allows your heel to shift, but moves your foot away from the kickstart lever. And i got information from dealer that if i remove kickstart lever the shaft fall into gearbox. by captinr » Mon Oct 12, 2015 6:29 am, Post are you suggesting this won't happen or do i still need to be worried about this?

by VWK75S » Thu May 03, 2018 5:19 am, Post You are going to find the puller pulls it so easy it is like you did not need it at all. Can anyone give me an easy way to get this K/S lever off the shaft so I can remove the clutch cover and finish what I've started? lube the splines and prise apart where the clamp section of the K/Start grips .then attempt to remove the K/Start . You didn't say what bike it is and type of lever, I'm presuming it's one with a pinch bolt style. However, most bikes have a built-in, simple and effective way to break loose a stubborn kickstarter-you just didn't know about it! 10:00. Its a 78 Husky and it is a pinch bolt tightened lever. Sorry for my english. You do not have the required permissions to view the files attached to this post. Are ya having a problem with your rig? - Shorter lever makes starting in tight spots easier But, if you have such a driver and it works, by all means use it.

Removing Kickstart Lever. by hotflash44 » Wed May 02, 2018 1:51 pm, Post 0 Members and 1 Guest are viewing this topic. There is probably a groove in the shaft, much like the gear selector shaft...that will not allow you to pull off lever(kickstarter) unless the bolts have been fully removed first. Also, the kickstarter my come in handy someday .

Kick Start Lever Repair #1 souperdoo. . As someone mentioned earlier, there is no split and pinch bolt that can be spread apart.

The only pinch bolt is on the upper part of the lever. by RobH » Sat May 05, 2018 1:50 am, Post ... How to Remove GY6 Kickstarter Gear, Stroker, Woodruff Keys, Oil Seal on 157QMJ - Duration: 29:56. General Hammerin' and Wrenchin' (all model years), ↳   General Hammerin' and Wrenchin' (all model years), ↳   2014 & Later Model-Specific Wrenching Issues, Kick start lever remove - riding without it, Re: Kick start lever remove - riding without it. I have used this many times over the years mainly on badly worn gear selector shafts/levers but also on kick start shafts/levers. Now fold open the lever as if you were going to kickstart the bike. An Independent Forum for Ural & Dnepr Motorcycle Enthusiasts since 2007, Post Post Remove the cotter pin with the pressure applied to the threaded end. Dr. Billy Glaser, author of the "Unofficial 750 Ural Service Manual" site myural.com, is moderating this section. Frame # TS1852-24007 up to TS1852-39022.

"/>

Copyright © 2020 Dirt Rider. Nothing is working. Whether screws available these days are JIS or Phillips is anyone's guess, but I would guess Phillips, not JIS, the differences being largely esoteric. It will slide outward on the splines about 1/16 of an inch and will go no further. The puller will pull straight up, where the other methods will tend to cock the part, causing it to bind. I'd most likely saturate it with that PB Blaster and then loosen/remove everything attached to and/or around the kicker apparatus and then hold your breath and pull straightforward. I like to think "It shouldn't be this hard" when I'm working on stuff then I try to think like the guys who made the item I'm working on and try to imagine what they'd do and then suddenly I break something. As others have mentioned, it takes some time to get use to the Ural layout. Loading... Unsubscribe from souperdoo? by brianural » Wed May 02, 2018 9:25 pm, Post A Bonnier Corporation Company. Fortunately, they weren't serious and it should function just fine. I have always been able to install the kicker without taking the clutch cover off, by removing the kick return rubber stopper. by jleewebb » Fri Oct 16, 2015 11:39 am, Post I have to do the same thing! Spray a little water on as you drill.This is also easier what of removing the kick starter as you can punch the roll pin out and replace it afterwards. The stock KDX kickstart is a piece of crap. by Lmo » Wed May 02, 2018 5:29 pm, Post Fixing a Cracked Motorcycle Engine Case / TS185 - Duration: 10:00. Using the 3-inch puller, I hosed the shaft and lever splines down with penetrant, pulled a bit, backed off, re-centered the tool and pulled it again.

The moral of the story? The picture/tutorial given in the FAQ section is on the money -- other than not covering those of us with K/S on our bikes.

Either it'll work or it won't.

RichardMott Posts: 552 Joined: Mon Jul 22, 2013 6:36 am Location: King of Prussia, Pa. Re: correct kick start lever installation. When i want to shift up by heel, everytime i hit to kickstart lever. I know it is very light alloy and subject to cracking. Then continue to unscrew the bolt; you'll notice the flange on most bikes' start lever overlaps the bolt. The dealer wanted $140 to R&R the water pump (and replace it with new). Then continue to unscrew the bolt; you'll notice the flange on most bikes' start lever overlaps the bolt. http://www.craftsman.com/shc/s/p_10155_12602_00946905000P?vName=Tools+%26+Equipment&cName=Hand+Tools&keyword=puller. The 3-jaw puller was not ideal. I use needle rollers about the width of the lever. Top. I am having some serious issues removing either the quadrant (ratchet) or the kick starter lever and then pushing the whole thing through. In theory, you should be able to pull that center-bolt out and slide the lever off its splines. How did it turn out? I would get about a milimeter movement each time, and ultimately, the thing popped off the splines. The bolt acts as a puller and should significantly loosen the starter lever so you can pull it off by hand.

by RichardMott » Mon Oct 12, 2015 7:15 am, Post

It does require drilling in the end of the shaft between the shaft and lever (round key type) I find a couple of 3 or 4 mm pins usually does the job. . 2005 Gear-Up, Mr. Nat_ural 108,000+ Kilometers and counting. I got the job done for about $35 -- which includes the $16 spent on buying the puller set. No big deal, I thought. 29:56 .

250 four-stroke motocross bike comparison. Whether it falls off when you really need it or is just stuck on the shaft when you want to take it off, kickstarters can be a hassle. Sure you can start the bike with your hand, but the lever is far too long, and gives you so much leverage, that it ends up wearing out the boss very quickly. Looks like a small jawed gear puller would do it -- but I don't have such a tool.

All the best, RPG, Less fatiguing to use your toe to push down to upshift- no shin splints. See, wasn't that easy? The shaft should press out of the quadrant. We'll try to help. by viclioce » Sat Oct 17, 2015 7:25 pm, Users browsing this forum: No registered users and 8 guests, Powered by phpBB® Forum Software © phpBB Limited, The main Page for the Hodaka Club Discussion Group, I just bought my first Hodaka, Dirt Squirt model 01. I use a small two jaw puller when they are stuck. Next stop: Tool store for a small gear puller. It has to come straight off the shaft.. if you do not pull it straight off it will bind. The original screws, so I hear, were JIS. by Bullfrog » Fri Oct 16, 2015 10:05 pm, Post KTM MC 250 77 Husky CR 360 77, Husky 82 420 Auto Bitsa XR 200 project. Don't flame, hate, spam. jo360 - justintendo replied above that the kick start spring and mechanism will unwind if I take the lever off without removing the case. Wanted - 1978 TS185 frame or frame&motor. ; D Victor, Re: correct kick start lever installation. Same one I recommend for the CS sprocket. I'll just remove the bolt holding the k/s lever on its splined shaft and pull the K/S lever. Offset is about 2" back and starts so angled part begins where lever sticks out from frame. Both are so on there it's like they're welded. It is important to keep an open mind.

I figured I could use them for other projects as well as this immediate need. The sacrificial bolt is a good concept. Better control in getting the right amount of "stomp" to shift up. First loosen the bolt holding the kickstarter, but don't remove it. I ended up buying a 3-puller set of 3-jaw pullers (3", 4", and 8" -- 16 bucks on sale) from Harbor Freight. A KX 125 lever can be retrofitted instead, and provides a few advantages. - Duration: 3:26. By The Ural's made Maine a much bigger state. You dont use the roll pins as the spline or drill them in from side you drill all the way thou the kick stater and the shaft one 5mm normaly works. All rights reserved. Reproduction in whole or in part without permission is prohibited.

It simply will not move past that 1/16 of an inch. PO removed kick starter for another bike. 2020 Glen Helen 2 EnduroCross Race Report, 2020 Glen Helen 1 EnduroCross Race Report, 2020 Fox Raceway National Motocross 250 Class Race Report, 2020 Fox Raceway National Motocross 450 Class Race Report, 2020 Off-Road Bikes—Jordan Graham’s Ducati Scrambler Desert Sled. Thanks to all who offered their advice on this topic! A 2-jaw puller would have been easier to center and would have likely made the job considerably faster, but the 3-jaw unit got the job done, ultimately. How to install the kick start gears on a 125-150cc GY6 four-stroke engine, common in scooters, ATVs, buggies, and karts. I'm interested in these for my 09 SM. The good thing about telling the truth is that you don't have to remember what you said. Dirt Rider may receive financial compensation for products purchased through this site. Single special bolt in the center, clamps in on. First loosen the bolt holding the kickstarter, but don't remove it.

The shaft should press out of the quadrant. I will likely go shopping this evening for a small jawed gear puller.

The bike is completely stock and original and runs great. Have you done it yet? fotosaurus, May 22, 2014 #9. stormer254 Husqvarna AA Class . That still allows your heel to shift, but moves your foot away from the kickstart lever. And i got information from dealer that if i remove kickstart lever the shaft fall into gearbox. by captinr » Mon Oct 12, 2015 6:29 am, Post are you suggesting this won't happen or do i still need to be worried about this?

by VWK75S » Thu May 03, 2018 5:19 am, Post You are going to find the puller pulls it so easy it is like you did not need it at all. Can anyone give me an easy way to get this K/S lever off the shaft so I can remove the clutch cover and finish what I've started? lube the splines and prise apart where the clamp section of the K/Start grips .then attempt to remove the K/Start . You didn't say what bike it is and type of lever, I'm presuming it's one with a pinch bolt style. However, most bikes have a built-in, simple and effective way to break loose a stubborn kickstarter-you just didn't know about it! 10:00. Its a 78 Husky and it is a pinch bolt tightened lever. Sorry for my english. You do not have the required permissions to view the files attached to this post. Are ya having a problem with your rig? - Shorter lever makes starting in tight spots easier But, if you have such a driver and it works, by all means use it.

Removing Kickstart Lever. by hotflash44 » Wed May 02, 2018 1:51 pm, Post 0 Members and 1 Guest are viewing this topic. There is probably a groove in the shaft, much like the gear selector shaft...that will not allow you to pull off lever(kickstarter) unless the bolts have been fully removed first. Also, the kickstarter my come in handy someday .

Kick Start Lever Repair #1 souperdoo. . As someone mentioned earlier, there is no split and pinch bolt that can be spread apart.

The only pinch bolt is on the upper part of the lever. by RobH » Sat May 05, 2018 1:50 am, Post ... How to Remove GY6 Kickstarter Gear, Stroker, Woodruff Keys, Oil Seal on 157QMJ - Duration: 29:56. General Hammerin' and Wrenchin' (all model years), ↳   General Hammerin' and Wrenchin' (all model years), ↳   2014 & Later Model-Specific Wrenching Issues, Kick start lever remove - riding without it, Re: Kick start lever remove - riding without it. I have used this many times over the years mainly on badly worn gear selector shafts/levers but also on kick start shafts/levers. Now fold open the lever as if you were going to kickstart the bike. An Independent Forum for Ural & Dnepr Motorcycle Enthusiasts since 2007, Post Post Remove the cotter pin with the pressure applied to the threaded end. Dr. Billy Glaser, author of the "Unofficial 750 Ural Service Manual" site myural.com, is moderating this section. Frame # TS1852-24007 up to TS1852-39022.

">

Copyright © 2020 Dirt Rider. Nothing is working. Whether screws available these days are JIS or Phillips is anyone's guess, but I would guess Phillips, not JIS, the differences being largely esoteric. It will slide outward on the splines about 1/16 of an inch and will go no further. The puller will pull straight up, where the other methods will tend to cock the part, causing it to bind. I'd most likely saturate it with that PB Blaster and then loosen/remove everything attached to and/or around the kicker apparatus and then hold your breath and pull straightforward. I like to think "It shouldn't be this hard" when I'm working on stuff then I try to think like the guys who made the item I'm working on and try to imagine what they'd do and then suddenly I break something. As others have mentioned, it takes some time to get use to the Ural layout. Loading... Unsubscribe from souperdoo? by brianural » Wed May 02, 2018 9:25 pm, Post A Bonnier Corporation Company. Fortunately, they weren't serious and it should function just fine. I have always been able to install the kicker without taking the clutch cover off, by removing the kick return rubber stopper. by jleewebb » Fri Oct 16, 2015 11:39 am, Post I have to do the same thing! Spray a little water on as you drill.This is also easier what of removing the kick starter as you can punch the roll pin out and replace it afterwards. The stock KDX kickstart is a piece of crap. by Lmo » Wed May 02, 2018 5:29 pm, Post Fixing a Cracked Motorcycle Engine Case / TS185 - Duration: 10:00. Using the 3-inch puller, I hosed the shaft and lever splines down with penetrant, pulled a bit, backed off, re-centered the tool and pulled it again.

The moral of the story? The picture/tutorial given in the FAQ section is on the money -- other than not covering those of us with K/S on our bikes.

Either it'll work or it won't.

RichardMott Posts: 552 Joined: Mon Jul 22, 2013 6:36 am Location: King of Prussia, Pa. Re: correct kick start lever installation. When i want to shift up by heel, everytime i hit to kickstart lever. I know it is very light alloy and subject to cracking. Then continue to unscrew the bolt; you'll notice the flange on most bikes' start lever overlaps the bolt. The dealer wanted $140 to R&R the water pump (and replace it with new). Then continue to unscrew the bolt; you'll notice the flange on most bikes' start lever overlaps the bolt. http://www.craftsman.com/shc/s/p_10155_12602_00946905000P?vName=Tools+%26+Equipment&cName=Hand+Tools&keyword=puller. The 3-jaw puller was not ideal. I use needle rollers about the width of the lever. Top. I am having some serious issues removing either the quadrant (ratchet) or the kick starter lever and then pushing the whole thing through. In theory, you should be able to pull that center-bolt out and slide the lever off its splines. How did it turn out? I would get about a milimeter movement each time, and ultimately, the thing popped off the splines. The bolt acts as a puller and should significantly loosen the starter lever so you can pull it off by hand.

by RichardMott » Mon Oct 12, 2015 7:15 am, Post

It does require drilling in the end of the shaft between the shaft and lever (round key type) I find a couple of 3 or 4 mm pins usually does the job. . 2005 Gear-Up, Mr. Nat_ural 108,000+ Kilometers and counting. I got the job done for about $35 -- which includes the $16 spent on buying the puller set. No big deal, I thought. 29:56 .

250 four-stroke motocross bike comparison. Whether it falls off when you really need it or is just stuck on the shaft when you want to take it off, kickstarters can be a hassle. Sure you can start the bike with your hand, but the lever is far too long, and gives you so much leverage, that it ends up wearing out the boss very quickly. Looks like a small jawed gear puller would do it -- but I don't have such a tool.

All the best, RPG, Less fatiguing to use your toe to push down to upshift- no shin splints. See, wasn't that easy? The shaft should press out of the quadrant. We'll try to help. by viclioce » Sat Oct 17, 2015 7:25 pm, Users browsing this forum: No registered users and 8 guests, Powered by phpBB® Forum Software © phpBB Limited, The main Page for the Hodaka Club Discussion Group, I just bought my first Hodaka, Dirt Squirt model 01. I use a small two jaw puller when they are stuck. Next stop: Tool store for a small gear puller. It has to come straight off the shaft.. if you do not pull it straight off it will bind. The original screws, so I hear, were JIS. by Bullfrog » Fri Oct 16, 2015 10:05 pm, Post KTM MC 250 77 Husky CR 360 77, Husky 82 420 Auto Bitsa XR 200 project. Don't flame, hate, spam. jo360 - justintendo replied above that the kick start spring and mechanism will unwind if I take the lever off without removing the case. Wanted - 1978 TS185 frame or frame&motor. ; D Victor, Re: correct kick start lever installation. Same one I recommend for the CS sprocket. I'll just remove the bolt holding the k/s lever on its splined shaft and pull the K/S lever. Offset is about 2" back and starts so angled part begins where lever sticks out from frame. Both are so on there it's like they're welded. It is important to keep an open mind.

I figured I could use them for other projects as well as this immediate need. The sacrificial bolt is a good concept. Better control in getting the right amount of "stomp" to shift up. First loosen the bolt holding the kickstarter, but don't remove it. I ended up buying a 3-puller set of 3-jaw pullers (3", 4", and 8" -- 16 bucks on sale) from Harbor Freight. A KX 125 lever can be retrofitted instead, and provides a few advantages. - Duration: 3:26. By The Ural's made Maine a much bigger state. You dont use the roll pins as the spline or drill them in from side you drill all the way thou the kick stater and the shaft one 5mm normaly works. All rights reserved. Reproduction in whole or in part without permission is prohibited.

It simply will not move past that 1/16 of an inch. PO removed kick starter for another bike. 2020 Glen Helen 2 EnduroCross Race Report, 2020 Glen Helen 1 EnduroCross Race Report, 2020 Fox Raceway National Motocross 250 Class Race Report, 2020 Fox Raceway National Motocross 450 Class Race Report, 2020 Off-Road Bikes—Jordan Graham’s Ducati Scrambler Desert Sled. Thanks to all who offered their advice on this topic! A 2-jaw puller would have been easier to center and would have likely made the job considerably faster, but the 3-jaw unit got the job done, ultimately. How to install the kick start gears on a 125-150cc GY6 four-stroke engine, common in scooters, ATVs, buggies, and karts. I'm interested in these for my 09 SM. The good thing about telling the truth is that you don't have to remember what you said. Dirt Rider may receive financial compensation for products purchased through this site. Single special bolt in the center, clamps in on. First loosen the bolt holding the kickstarter, but don't remove it.

The shaft should press out of the quadrant. I will likely go shopping this evening for a small jawed gear puller.

The bike is completely stock and original and runs great. Have you done it yet? fotosaurus, May 22, 2014 #9. stormer254 Husqvarna AA Class . That still allows your heel to shift, but moves your foot away from the kickstart lever. And i got information from dealer that if i remove kickstart lever the shaft fall into gearbox. by captinr » Mon Oct 12, 2015 6:29 am, Post are you suggesting this won't happen or do i still need to be worried about this?

by VWK75S » Thu May 03, 2018 5:19 am, Post You are going to find the puller pulls it so easy it is like you did not need it at all. Can anyone give me an easy way to get this K/S lever off the shaft so I can remove the clutch cover and finish what I've started? lube the splines and prise apart where the clamp section of the K/Start grips .then attempt to remove the K/Start . You didn't say what bike it is and type of lever, I'm presuming it's one with a pinch bolt style. However, most bikes have a built-in, simple and effective way to break loose a stubborn kickstarter-you just didn't know about it! 10:00. Its a 78 Husky and it is a pinch bolt tightened lever. Sorry for my english. You do not have the required permissions to view the files attached to this post. Are ya having a problem with your rig? - Shorter lever makes starting in tight spots easier But, if you have such a driver and it works, by all means use it.

Removing Kickstart Lever. by hotflash44 » Wed May 02, 2018 1:51 pm, Post 0 Members and 1 Guest are viewing this topic. There is probably a groove in the shaft, much like the gear selector shaft...that will not allow you to pull off lever(kickstarter) unless the bolts have been fully removed first. Also, the kickstarter my come in handy someday .

Kick Start Lever Repair #1 souperdoo. . As someone mentioned earlier, there is no split and pinch bolt that can be spread apart.

The only pinch bolt is on the upper part of the lever. by RobH » Sat May 05, 2018 1:50 am, Post ... How to Remove GY6 Kickstarter Gear, Stroker, Woodruff Keys, Oil Seal on 157QMJ - Duration: 29:56. General Hammerin' and Wrenchin' (all model years), ↳   General Hammerin' and Wrenchin' (all model years), ↳   2014 & Later Model-Specific Wrenching Issues, Kick start lever remove - riding without it, Re: Kick start lever remove - riding without it. I have used this many times over the years mainly on badly worn gear selector shafts/levers but also on kick start shafts/levers. Now fold open the lever as if you were going to kickstart the bike. An Independent Forum for Ural & Dnepr Motorcycle Enthusiasts since 2007, Post Post Remove the cotter pin with the pressure applied to the threaded end. Dr. Billy Glaser, author of the "Unofficial 750 Ural Service Manual" site myural.com, is moderating this section. Frame # TS1852-24007 up to TS1852-39022.

">

how to remove kick start lever

I am wondering if the kick start lever retaining screw actually fits onto a carved out section of the shaft and the screw must be FULLY removed to separate the lever from the shaft.. Next for my 2 DRZs: Installing Soupy's adjustable lowering links. There is another philips screw on the lever, but it appears to be a pinch for the extended portion of the lever (to attach it to the splined base). Did you pull the pinch bolts all the way out?? Then just put the rubber stopped back in. where would i find a small 2 jaw small puller though? by otompotom » Thu May 03, 2018 1:48 am, Post I tried to use the frame as my fulcrum point...although I did use some parts of the case where it has compound bends (strongest), but never subjected it to anything worse than steady pressure....Used PB Blaster (like a super WD-40), but no luck there, either. Share your tech tips and experiences here. Location: England Husqvarna Motorcycle: More than I dare let her know Other Motorcycles: Yes! And yes, I've had the "It shouldn't be this hard" moment at several points during the evening. Nathans Idea is a very good one as a temporary repair. mrgem mrgem TT Silver Member; Members; 544 posts; Location: Colorado; Posted June 15, 2010. by jaybird » Thu May 03, 2018 11:19 am, Post When you shift with your heel, point your toes away from the bike. Any 60's or 70's triump/BSA/Norton has them. IMHO. Should have nothing to do with the lower part and the splined shaft. Copyright© ThumperTalk, Inc. - All rights reserved.

Copyright © 2020 Dirt Rider. Nothing is working. Whether screws available these days are JIS or Phillips is anyone's guess, but I would guess Phillips, not JIS, the differences being largely esoteric. It will slide outward on the splines about 1/16 of an inch and will go no further. The puller will pull straight up, where the other methods will tend to cock the part, causing it to bind. I'd most likely saturate it with that PB Blaster and then loosen/remove everything attached to and/or around the kicker apparatus and then hold your breath and pull straightforward. I like to think "It shouldn't be this hard" when I'm working on stuff then I try to think like the guys who made the item I'm working on and try to imagine what they'd do and then suddenly I break something. As others have mentioned, it takes some time to get use to the Ural layout. Loading... Unsubscribe from souperdoo? by brianural » Wed May 02, 2018 9:25 pm, Post A Bonnier Corporation Company. Fortunately, they weren't serious and it should function just fine. I have always been able to install the kicker without taking the clutch cover off, by removing the kick return rubber stopper. by jleewebb » Fri Oct 16, 2015 11:39 am, Post I have to do the same thing! Spray a little water on as you drill.This is also easier what of removing the kick starter as you can punch the roll pin out and replace it afterwards. The stock KDX kickstart is a piece of crap. by Lmo » Wed May 02, 2018 5:29 pm, Post Fixing a Cracked Motorcycle Engine Case / TS185 - Duration: 10:00. Using the 3-inch puller, I hosed the shaft and lever splines down with penetrant, pulled a bit, backed off, re-centered the tool and pulled it again.

The moral of the story? The picture/tutorial given in the FAQ section is on the money -- other than not covering those of us with K/S on our bikes.

Either it'll work or it won't.

RichardMott Posts: 552 Joined: Mon Jul 22, 2013 6:36 am Location: King of Prussia, Pa. Re: correct kick start lever installation. When i want to shift up by heel, everytime i hit to kickstart lever. I know it is very light alloy and subject to cracking. Then continue to unscrew the bolt; you'll notice the flange on most bikes' start lever overlaps the bolt. The dealer wanted $140 to R&R the water pump (and replace it with new). Then continue to unscrew the bolt; you'll notice the flange on most bikes' start lever overlaps the bolt. http://www.craftsman.com/shc/s/p_10155_12602_00946905000P?vName=Tools+%26+Equipment&cName=Hand+Tools&keyword=puller. The 3-jaw puller was not ideal. I use needle rollers about the width of the lever. Top. I am having some serious issues removing either the quadrant (ratchet) or the kick starter lever and then pushing the whole thing through. In theory, you should be able to pull that center-bolt out and slide the lever off its splines. How did it turn out? I would get about a milimeter movement each time, and ultimately, the thing popped off the splines. The bolt acts as a puller and should significantly loosen the starter lever so you can pull it off by hand.

by RichardMott » Mon Oct 12, 2015 7:15 am, Post

It does require drilling in the end of the shaft between the shaft and lever (round key type) I find a couple of 3 or 4 mm pins usually does the job. . 2005 Gear-Up, Mr. Nat_ural 108,000+ Kilometers and counting. I got the job done for about $35 -- which includes the $16 spent on buying the puller set. No big deal, I thought. 29:56 .

250 four-stroke motocross bike comparison. Whether it falls off when you really need it or is just stuck on the shaft when you want to take it off, kickstarters can be a hassle. Sure you can start the bike with your hand, but the lever is far too long, and gives you so much leverage, that it ends up wearing out the boss very quickly. Looks like a small jawed gear puller would do it -- but I don't have such a tool.

All the best, RPG, Less fatiguing to use your toe to push down to upshift- no shin splints. See, wasn't that easy? The shaft should press out of the quadrant. We'll try to help. by viclioce » Sat Oct 17, 2015 7:25 pm, Users browsing this forum: No registered users and 8 guests, Powered by phpBB® Forum Software © phpBB Limited, The main Page for the Hodaka Club Discussion Group, I just bought my first Hodaka, Dirt Squirt model 01. I use a small two jaw puller when they are stuck. Next stop: Tool store for a small gear puller. It has to come straight off the shaft.. if you do not pull it straight off it will bind. The original screws, so I hear, were JIS. by Bullfrog » Fri Oct 16, 2015 10:05 pm, Post KTM MC 250 77 Husky CR 360 77, Husky 82 420 Auto Bitsa XR 200 project. Don't flame, hate, spam. jo360 - justintendo replied above that the kick start spring and mechanism will unwind if I take the lever off without removing the case. Wanted - 1978 TS185 frame or frame&motor. ; D Victor, Re: correct kick start lever installation. Same one I recommend for the CS sprocket. I'll just remove the bolt holding the k/s lever on its splined shaft and pull the K/S lever. Offset is about 2" back and starts so angled part begins where lever sticks out from frame. Both are so on there it's like they're welded. It is important to keep an open mind.

I figured I could use them for other projects as well as this immediate need. The sacrificial bolt is a good concept. Better control in getting the right amount of "stomp" to shift up. First loosen the bolt holding the kickstarter, but don't remove it. I ended up buying a 3-puller set of 3-jaw pullers (3", 4", and 8" -- 16 bucks on sale) from Harbor Freight. A KX 125 lever can be retrofitted instead, and provides a few advantages. - Duration: 3:26. By The Ural's made Maine a much bigger state. You dont use the roll pins as the spline or drill them in from side you drill all the way thou the kick stater and the shaft one 5mm normaly works. All rights reserved. Reproduction in whole or in part without permission is prohibited.

It simply will not move past that 1/16 of an inch. PO removed kick starter for another bike. 2020 Glen Helen 2 EnduroCross Race Report, 2020 Glen Helen 1 EnduroCross Race Report, 2020 Fox Raceway National Motocross 250 Class Race Report, 2020 Fox Raceway National Motocross 450 Class Race Report, 2020 Off-Road Bikes—Jordan Graham’s Ducati Scrambler Desert Sled. Thanks to all who offered their advice on this topic! A 2-jaw puller would have been easier to center and would have likely made the job considerably faster, but the 3-jaw unit got the job done, ultimately. How to install the kick start gears on a 125-150cc GY6 four-stroke engine, common in scooters, ATVs, buggies, and karts. I'm interested in these for my 09 SM. The good thing about telling the truth is that you don't have to remember what you said. Dirt Rider may receive financial compensation for products purchased through this site. Single special bolt in the center, clamps in on. First loosen the bolt holding the kickstarter, but don't remove it.

The shaft should press out of the quadrant. I will likely go shopping this evening for a small jawed gear puller.

The bike is completely stock and original and runs great. Have you done it yet? fotosaurus, May 22, 2014 #9. stormer254 Husqvarna AA Class . That still allows your heel to shift, but moves your foot away from the kickstart lever. And i got information from dealer that if i remove kickstart lever the shaft fall into gearbox. by captinr » Mon Oct 12, 2015 6:29 am, Post are you suggesting this won't happen or do i still need to be worried about this?

by VWK75S » Thu May 03, 2018 5:19 am, Post You are going to find the puller pulls it so easy it is like you did not need it at all. Can anyone give me an easy way to get this K/S lever off the shaft so I can remove the clutch cover and finish what I've started? lube the splines and prise apart where the clamp section of the K/Start grips .then attempt to remove the K/Start . You didn't say what bike it is and type of lever, I'm presuming it's one with a pinch bolt style. However, most bikes have a built-in, simple and effective way to break loose a stubborn kickstarter-you just didn't know about it! 10:00. Its a 78 Husky and it is a pinch bolt tightened lever. Sorry for my english. You do not have the required permissions to view the files attached to this post. Are ya having a problem with your rig? - Shorter lever makes starting in tight spots easier But, if you have such a driver and it works, by all means use it.

Removing Kickstart Lever. by hotflash44 » Wed May 02, 2018 1:51 pm, Post 0 Members and 1 Guest are viewing this topic. There is probably a groove in the shaft, much like the gear selector shaft...that will not allow you to pull off lever(kickstarter) unless the bolts have been fully removed first. Also, the kickstarter my come in handy someday .

Kick Start Lever Repair #1 souperdoo. . As someone mentioned earlier, there is no split and pinch bolt that can be spread apart.

The only pinch bolt is on the upper part of the lever. by RobH » Sat May 05, 2018 1:50 am, Post ... How to Remove GY6 Kickstarter Gear, Stroker, Woodruff Keys, Oil Seal on 157QMJ - Duration: 29:56. General Hammerin' and Wrenchin' (all model years), ↳   General Hammerin' and Wrenchin' (all model years), ↳   2014 & Later Model-Specific Wrenching Issues, Kick start lever remove - riding without it, Re: Kick start lever remove - riding without it. I have used this many times over the years mainly on badly worn gear selector shafts/levers but also on kick start shafts/levers. Now fold open the lever as if you were going to kickstart the bike. An Independent Forum for Ural & Dnepr Motorcycle Enthusiasts since 2007, Post Post Remove the cotter pin with the pressure applied to the threaded end. Dr. Billy Glaser, author of the "Unofficial 750 Ural Service Manual" site myural.com, is moderating this section. Frame # TS1852-24007 up to TS1852-39022.

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