So I was out on the trails alone Saturday afternoon when I had a small spill. My knee guard hit the start button and it popped out. I didn't know it until I went to start the bike and found it a little unusual no button was there. Well I found the button on the ground and got it back in but the spring popped out as well and without the spring the button doesn't make the connection to start. I didn't have a Phillips to open up the switch and I was at the bottom of a hill so no easy jump-starting. So is needless to say I was f**cked and it was getting late and nobody seemed to be coming by the section of trails I was in. So I set a waypoint on my GPS and left my bike. After about a half mile walking up and down some hills in my MX boots I finally came across a 4-wheeler. He volunteered to help and we went back towards my bike. The trails were tight and the 4-wheeler wasn't having an easy time and to top it off my GPS was having a hard time getting a signal because of all the trees so it took us a while to find my bike. He had a Phillips and we got the start/kill switch open and used the Phillips to complete the circuit and start the bike.

So a few things I learned by this adventure. First, not having a kick-starter sucks *****. This is the second time the bike has stranded me and both times a kick-starter would have saved the day. Second, never ride alone. I've done it so many times but it just isn't safe and this could have turned out much worse. Also, have some basic tools, I had an Allan head set and an adjustable wrench but I should have had a Phillips as well.

I found that the horn button uses the same spring as the start button so I switched that over for now. Unfortunately Kawasaki doesn't sell just a spring and the whole switch costs $35. If anyone knows of where I can get a spring like this or has a start or light switch they don't use any more so I can get the spring out of it please let me know.

 

Hey man glad to hear you got through it OK, I know that riding by myself I always think of what could happen. I still think about the kick start kit, and am still tempted to do it. Silver Otter offered to help me with it if I bought the parts, and he's only about 3 hrs from me, I might just take him up on the offer some day. Question, what happened to your stock tool kit? Did you ditch the tool bag? I know a lot of guys have. I always take extra tools with me if I'm going out of town or off road. I periodically do 70 mile rides out in the old behind the gates where I know nobody is around, I hope I don't get stranded someday.

 

its not too hard to push start the bike Iv had to do that when my battery died

 

hey typesh, how big is the spring, can u improvise, for instance will a spring out of a click type pen work?

 

Yeah, that's what I was going to suggest. Pens, Bic style lighters, kid toys, etc. all have small springs.

I guess this was after me and Charlie left for the day? I'm glad you got out OK, Red River is a bad place to get stranded. [:'(]

We both had a great time riding with you and we need to do it again sometime! Post some of those pitcures up, or at least send them to me via email.

 

Macgyver.....what.....what.....what's he doing with that thing?

 

haha that sucks, glad to hear your alright after the whole deal tho

 

I changed out my e-start switch with a cheapo Radio Shack 3-amp momentary switch..the OEM one popped out of position and stuck in the on position after the bike had started...not good for strater. I know at least one other person has swapped theirs out too, can't remember who though.

Mooredan had recommended a great looking control set to replace the OEM one as well..I'll see if i can find it

here's what I did...


and just taped th OEM hole with black electrical tape for now...

 

Looks good mudjunkie. As far as the taped area? Use a piece of abs sheet and weld it to the housing. ie MEK with abs shavings for a liquid weld.

 

what's MEK?...A friend of mine used to have a plastic welder for welding up ATV fenders and such, but I dunno if one of those would work (I never got a chance to see one in action)