Author Topic: kickstart spring/engine case woes  (Read 2114 times)

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Offline iamsofaking

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kickstart spring/engine case woes
« on: March 17, 2009, 03:36:33 AM »
I had a problem with my kickstarter not engaging all the time on my '86 so I bought some new bits for it and set to installing them.  When I go to put humpty all back together again, there is a fairly substantial bit missing from the hole where the spring tucks into the engine case.  I can't for the life of me get the little bugger to stay in there with what is left of the hole.  I bought a new set of engine cases from ebay, but they have the same notch missing!  Has anyone experienced this?  Seems a little oily in there for JB weld.  I suppose I could take it all down and bring it to the machine shop to see what they can do.  I am hoping that someone here has dealt with this and knows a little trick that will get my riding again, or a place where I can get a case in good shape.
Thanks for reading.

Offline KX500freak

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Re: kickstart spring/engine case woes
« Reply #1 on: March 17, 2009, 03:49:04 AM »
yea ,i have one enginecase where that happened too.
previous owner did weld it back on twice as thick ,so it would not come off again .
it is a weak spot in the design imho :|
i think you will end up the same way here,
dunno if JB weld holds in places where tension builds up ,using the kicker ,stretching the spring..

succes with it !!
Dutch Team Green 91-94-01 KX500

Offline Danger4u2

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Re: kickstart spring/engine case woes
« Reply #2 on: March 17, 2009, 03:57:47 AM »
This hole, yes??
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Offline iamsofaking

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Re: kickstart spring/engine case woes
« Reply #3 on: March 17, 2009, 04:04:16 AM »
Right.  The one where the spring hooks into the case there.  I can send a picture tonight if it helps, but my gimmick is not as clean as yours.  Very nice.

Offline Danger4u2

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Re: kickstart spring/engine case woes
« Reply #4 on: March 17, 2009, 04:07:14 AM »
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Offline JBKX

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Re: kickstart spring/engine case woes
« Reply #5 on: March 17, 2009, 04:07:58 AM »
Same thing happened to me some years ago.  I bent the end of the spring that goes in the hole so it hooks just a bit.  I had to drive the end into the hole, however it hasn't tripped out yet.  I don't ride that bike much so I can't tell you how long it'll last with regular usage.
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Offline KXT500

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Re: kickstart spring/engine case woes
« Reply #6 on: March 17, 2009, 07:43:51 AM »
any shop that works on aluminum heads or radiators should be able to weld that up in a couple seconds. redill the hole and rock on. no need for new cases.