250 Broke my SHAFT KICK

JamesKX250

JamesKX250

So I was riding this past weekend with few buddies in the northern Michigan woods (West Higgins Lake Loop) to be exact and about 15-20 minutes into the ride we stopped to cross the road and I had to re start the bike, after couple tries SHITTTT, damn kick starter breaks off, after a closer look the actual shaft broke (Part # 13066 Shaft Kick) I had to try to keep the bike alive for the rest of the ride and push start it couple times, we still got about 50 miles of woods riding in :)

I will post couple pics of the actual break tomorrow, I guess I will have to take apart Kickstarter Mechanism and hopefully get this fixed in the next week or two. 45103.png
 
2smoke

2smoke

:thumbsdown: That sucks. Well Im unsure if you have to split the cases to replace that. I think :thinking: all you have to do is drain the oil remove the clutch cover, clutch assy, and the case half cover to get it out and replace it. Ive never done that job before so Im speculating.
 
JamesKX250

JamesKX250

2smoke:
:thumbsdown: That sucks. Well Im unsure if you have to split the cases to replace that. I think :thinking: all you have to do is drain the oil remove the clutch cover, clutch assy, and the case half cover to get it out and replace it. Ive never done that job before so Im speculating.
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I really thought I was done wrenching on this thing for at least 2 months and then this shit happens... Joys of buying a used bike :(
 
JamesKX250

JamesKX250

JamesKX250:
So I was riding this past weekend with few buddies in the northern Michigan woods (West Higgins Lake Loop) to be exact and about 15-20 minutes into the ride we stopped to cross the road and I had to re start the bike, after couple tries SHITTTT, damn kick starter breaks off, after a closer look the actual shaft broke (Part # 13066 Shaft Kick) I had to try to keep the bike alive for the rest of the ride and push start it couple times, we still got about 50 miles of woods riding in :)

I will post couple pics of the actual break tomorrow, I guess I will have to take apart Kickstarter Mechanism and hopefully get this fixed in the next week or two. View attachment 15668
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http://www.ebay.com/itm/NEW-KICK-ST...Parts_Accessories&hash=item43bbd5bde8&vxp=mtr
 
2smoke

2smoke

Sad but true. And sometimes stupid stuff happens. I just put new levers on my bike. Had it out riding. Leaned it up against a fence to take a break. Wind came up and blew it over. Snapped my new clutch lever right off at the retention bolt.
 
JamesKX250

JamesKX250

James:
Dang, can't say I've ever seen that happen before.

You might not have to drain the oil, just tip the bike on its side.
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I ripped her apart, drained the oil, had to drain the coolant as well... got super deep in there haha... I ll post pics now.
 
JamesKX250

JamesKX250

In order to remove the broken Kick Start Shaft I had to drain gear oil, drain coolant, split the clutch case, take off water pump, etc... PAIN IN THE ASS.. I blame the break on Kawasaki Factory for installing a short screw (seen in pic one) while there is clearly enough clearance for a longer screw (seen in pic 2) If I knew this before I would have replaced this 1/2 inch screw with a longer screw. I plan on doing that as soon as I get the new Kick Start Shaft... 20130522_201504.jpg20130522_192440.jpg20130522_203816.jpg20130522_203826.jpgSHAFT KICK.JPG20130522_193442.jpg20130522_200031.jpg20130522_200040.jpg20130522_200056.jpg20130522_200102.jpg20130522_200113.jpg20130522_200542.jpg20130522_200821.jpg20130522_201249.jpg20130522_201400.jpg
 
JamesKX250

JamesKX250

SRAD97750:
The short bolt was the reason for the failure. That shaft requires the bolt to be occupy most of the threads available. -BIG DAN:thumb:
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Yeah I know, some cocksucker figured this short bolt would work which just made my day past weekend. I had to push start the bike 5-6 times in the woods...
 
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