Kickstarter Install w/pics
 

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
Attachment 33011

No problem, nothing a beer and some calipers can't resolve
Attachment 33012

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.
Attachment 33013 [/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
Attachment 33014

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)
Attachment 33015

Now remove the whole left side cover......notice how big and nice our stator looks at least from my marine point of view.
Attachment 33016

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.
Attachment 33017[/align][/align]Clutch came off no problem, but it did take a little technique and patience... here's the removed right side clutch basket.
Attachment 33018

Here's a pic of the right side after clutch removal.
Attachment 33019

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.
https://img.photobucket.com/albums/v...t/DSC01014.jpg

Here's another view of the kickstart shaft, notice I'm getting low on parts
Attachment 33020

Now install the Idle Gear....no biggie just a circle clip and shims.
Attachment 33021

Slide in the kickstart shaft and Tension the spring 3/4 revolution counter clockwise so it locks in the engine case with tension.
Attachment 33022

Reinstall clutch
Attachment 33023[/align][/align]Put left side cover back on
Attachment 33024

Tighten up and finish the left side
Attachment 33025

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
Attachment 33026[/align][/align]Ok, footpeg and skid plate off
Attachment 33027[/align][/align]Hey, I think I spy a kickstarter
Attachment 33028
[/align]

RE: Kickstarter Install w/pics
 

No thanks, I'm not that good.;)

RE: Kickstarter Install w/pics
 

All done.....post and critique away. :D

RE: Kickstarter Install w/pics
 

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....

RE: Kickstarter Install w/pics
 

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

RE: Kickstarter Install w/pics
 

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

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

RE: Kickstarter Install w/pics
 

I am TOTALLY IMPRESSED!!

Nice job man!!!!!

RE: Kickstarter Install w/pics
 

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.

RE: Kickstarter Install w/pics
 

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?

RE: Kickstarter Install w/pics
 

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?

RE: Kickstarter Install w/pics
 

I didnt see where all these parts went after this pic
Attachment 33010


and Im not too clear about the 3/4 tension on the spring, but other than that its a great write-up. Thank you.

RE: Kickstarter Install w/pics
 

nice work on the kick starter. i would never be able to do that. i would get all confused. but already ahve the kick start on mine :Dbut then again i do not have the electric start either [:@]:(

RE: Kickstarter Install w/pics
 

Great post. You blazed the way for many to follow! I thought it would be a lot harder to install a kick start but after seeing this it doesn't look bad at all! [sm=smiley20.gif]

RE: Kickstarter Install w/pics
 

The kickstart shaft has a hole drilled in it.....one end of the spring goes in the shaft.....the other end of the spring gets shoved in the engine case....... you rotate the spring to maintain pressure on the shaft so it flicks back up after you kick it. I don't know how else to explain it.

RE: Kickstarter Install w/pics
 

Nice job, excellent write up

RE: Kickstarter Install w/pics
 

Excellent write-up!

Is there any clearance problem between the kick starter arm and the exhaust pipe? It looks like it's gonna be pretty close.

RE: Kickstarter Install w/pics
 

they(kawasaki) should offer some "off-road" kit that comes from the factory with like say high performance cams, kickstart, more rugged exterior protection(gaurds), lighten up, etc...

RE: Kickstarter Install w/pics
 

The Kickstarter Clears my muzzy header.....no problem.

RE: Kickstarter Install w/pics
 

Awesome!

RE: Kickstarter Install w/pics
 

yea he did a good job, i saw it in person. looks good

RE: Kickstarter Install w/pics
 

To hold the clutch, a penny between the clutch gear and the primary gear works good.

And then you have to lean to kick start it. Not that easy
________
Live sex

RE: Kickstarter Install w/pics
 

looks good...was wondering what all was involved in doin this.

how much did all of the stuff cost? and did you have to add some type of decompression switch, or is it still not that hard to kickstart it?

RE: Kickstarter Install w/pics
 

Anybody know if it's possible to ditch the starter motor altogether?

RE: Kickstarter Install w/pics
 

With the right tecnique it's easy to kickstart

RE: Kickstarter Install w/pics
 

Why wouldnt it be? You might need a new side cover where the starte hits the flywheel, if you take the starter off there would probably bea hole... a klx300 side cover would probably work.

RE: Kickstarter Install w/pics
 

Thread fixed.

Nope the bike comes with decompression gizmo on the cam shafts......works like a champ and has saved me at least four times in bad situations......ALLMOLES SHOULD HAVE A KICKSTARTER :D

RE: Kickstarter Install w/pics
 

Yikes! I'll send you a plane ticket to put mine in!

RE: Kickstarter Install w/pics
 

Same here, probably be cheaper than a mechanic too!

RE: Kickstarter Install w/pics
 

Nice write up

Did the beer come with the kit??

RE: Kickstarter Install w/pics
 

Good to hear that, FM.

On latermodels of the KLX300, Kawiwent with different timing on the ACR to make thekick starting easier and take some stress off of the idle gear.Itmight be worthlooking for an exhaust cam on ebay or getting with Brewster at Thumpertalk about repositioning your ACR. I don't recall what year the change started but you can see when thePN changed on the KLX300part fich.

RE: Kickstarter Install w/pics
 

Could we get the part list breakdown & aprox cost ?

This looks like a good winter project for my inbound bike.

Thx

RE: Kickstarter Install w/pics
 

Excellent job and write up!

It's too bad they don't come with a kickstarter from the factory, even worse isthe little plastic plug that says "kickstarter" just sittin' there teasing me and all.

Kickstarters have saved me many times on other bikes, I need to strongly consider this install.

One year later....


phwee finnaly found this old thread :D

is there anybody can tell me where to find kick starter set for 09 versions? i ask my dealer here and they aint got anything about kick starter for the bike..

help help me please :confused:

Wow, it seems like its been longer than a year.

Hey athan, I just checked your 09 engine part #s to those on my 06, all the part #s that interact with the kick starter mechanism are the same, so an 06 kickstart kit should work just fine.

My guess is that kawi, just dropped the ball and forgot to list an optional parts section for the 09 or they just want to get out of the kickstart business.

Babbits had the best price when I bought mine....I think it was $270.

Edit: lol...its been 2 years. 1/10/07.....thats more like it...thought I was loosing it there for a second.

Do it and post results...:D

haha 2 years....

hmm babbits? what do you mean? im not living in america, do you have some site that sells it? for $100 maybe hehe..

Yeah, that's kinda interesting. I'm wondering if the electic fuel pump on the EFI models will still put out enough pressure with a very low battery to get the bike started using a kick starter.
I noticed that the new EFI KX450F is kick start with EFI and starts in only one kick, but that whole electrical system is designed around the bike being kickstart.

I think Athan's bike might be EFI, so it'll be interesting to see the results. Don't be suprised, Athan, if you get a request from me to remove the batt and see if you can start still start it with your leg! Good luck!

yes mine's EFI but im still learning around motorcycle engine basic hehe...

Anyone install a kickstart on an '09 yet? Would love to put one on mine.

planning on it this winter! will let you guys know as it progresses...

Hey guys. I just ordered the kit from mrcycles.com for about $270. Seems Babbitts raised their price since '07. I won't be home to install it till maybe mid January. If any of you guys install one in an '09 before then, please post up the results. Thanks.

Matt