Here's some pics and limited instructions of me installing the kickstart kit on our little klx. Please note I'm used to working on outboards and other marine stuff...... this bike stuff is a little new to me. [/align][/align]Here's the kickstart kit out of the bag, notice all the washers and shims with no bags or part #s


No problem, nothing a beer and some calipers can't resolve


Drain oil and coolant......remove water pump cover and associated impeller and the rear brake pedal with associated springs, don't forget to remove the clutch cable clip. Now remove right side cover and you should look like this.
[/align][/align]Well at this point I wanted to install a part so I put on the ratchet gear kick guide....only 32 parts to go


Unfortunately, the idle gear goes under the clutch, so the left side cover needs to be removed to hold flywheel while removing the clutch. First to go is the left side e-start gear gizmo (technical term)


Now remove the whole left side cover......notice how big and nice our stator looks at least from my marine point of view.


Now you're supposed to use Kawi special tool part no blah, blah......I used a $2.99 harbor freight pipe wrench along with my Utah skid plate to hold the fly wheel while I grabbed and removed the clutch.
[/align][/align]Clutch came off no problem, but it did take a little technique and patience... here's the removed right side clutch basket.


Here's a pic of the right side after clutch removal.


Ok, now I started to assemble the kickstarter itself.......make sure ya line up the indent on the shaft spline with the indent on the ratchet gear, hope you can see it in the pic.


Here's another view of the kickstart shaft, notice I'm getting low on parts


Now install the Idle Gear....no biggie just a circle clip and shims.


Slide in the kickstart shaft and Tension the spring 3/4 revolution counter clockwise so it locks in the engine case with tension.


Reinstall clutch
[/align][/align]Put left side cover back on


Tighten up and finish the left side


Damn, with the kickstarter shaft I couldn't get the right side cover on due to the foot peg placement...... and after all this I gotta take off the skid plate to take off the foot peg See
[/align][/align]Ok, footpeg and skid plate off
[/align][/align]Hey, I think I spy a kickstarter

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No thanks, I'm not that good.

 

All done.....post and critique away.

 

Very, very nice work!

One comment that will probably make you want to throw darts at my picture though.... If you put the bike in gear, deflate the rear tire, stick a short piece of 2x4 between thetireand foreward part of theswingarm then re-inflate the tire (not fully), youcankeep everything from turningwithouthaving to pull the left cover and find a strap wrench.

Your way was more proper, but I'm just saying....

 

Great work, Finger Mullet, and nice photos. Now we know exactly what to expect. Thanks!

 

Awesome! Lemme ship my bike to you to put mine on

I'd like the kick start for a back up... foolish that its not on there!

 

I am TOTALLY IMPRESSED!!

Nice job man!!!!!

 

BTW, when the right side cover is off like that, its always a good idea to clean the oil screen, since that's usually the only time you have access to it. Looks like it slides out just below the clutch basket in your photos.

 

Man that was one of the best write up and picture posts to date, that being said, its not something I feel comfortable doing. Dang Kawasaki, I would have paid another $500.00 extra if they would have included it from the factory. So parts were what again? I wonder what the shop time estimate is to do this? I might have to get this done someday. And before someone flames me for not doing it myself, I have this fear about taking anything too complicated apart on a bike, 20 years ago I took a Yamaha 650 engine apart trying to find the tapping sound, and lets just say I sold it in boxes.[sm=trust_me.gif]I know my limitations.[8D] Oh yea and I don't want to do anything to mess up the 4 years I have left on the warranty. Man I can't believe its been 13 months since I brought the green machine home. I promised I wouldn't do this......[sm=boohoo.gif]OK deej pull it together.I might print out the pictures just to show the shop and see what they say. Hey maybe I could hire the mechanic on the side. I wonder what his favorite beer is?

 

Sticking a gear inbetween the primary gear & the gear on the clutch basket would accomplish the same thing as holding the flywheel, but I dont see how either would hold the clutch nut still when trying to remove it or tighten it. There must have been enough grab in the clutch to hold everything still for you.

Im thinking back to when I rebuilt my RM 125 engine & had to put that nut on/off with an air impact because I could not hold it still. Even if I locked the outer basket & fiiber plates, the inner basket & steel plates still spun when turning the nut.[sm=dontgetit.gif]

Nice writeup, thanks for all the info & trailblazing. I think if you took the clutch apart then had the tool to hold the inner basket removiung the other side covers would not be necessary?