Kickstarter Repair

[Lloyd Boland]

John & Mike, what do you think about this solution.  When I returned the motor back to the shop, the mechanic said he did not disassemble the kickstarter mechanism.  He worked on it today, looked at the manual and loosened the kickstarter stop bolt, wound the kickstarter shaft and then re-installed the kickstarter stop bold again.  He says it is working perfect.  I'm on my way to go pick it up.  Wish me luck.  Any comments?

[Kip Kern]

Sounds like he got it!  Three things to watch on the KTM KS mech.  (after assembled) At least 1mm clearance between the ratchet wheel and ratchet wheel lock gear so as to ensure free spin, About one full rotation of the KS shaft spring for proper action before installation of the KS stop bolt, and Make sure the spring is in the proper hole in the KS gear.  Some KS gears have two spring holes and the correct one is the hole behind the raising curve on the gear (same with Sachs)!:)