94 RM250 Kick Lever Removal

YZ125Ken
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YZ125Ken
Edited Date/Time 2/25/2016 10:39am
Trying to get the old kick starting lever off my bike to replace it with a new one. The old lever is very sloppy and does not stay folded while riding. It has a 6mm allen type head bolt holding it on but no matter how hard by hand I try to get it loose, it won't budge.

Could this be one of those reverse threaded deals by chance?

I have blasted it with PB Blaster but nothing. I'm thinking of locating a 6mm allen head for my Milwaukee 3/8" impact and powering it off. If that doesn't work, I guess I'm looking at the old Dremel and a cutoff wheel.

Any help or tips on this would be greatly appreciated.

Thank you!



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FGR01
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FGR01 2/22/2016 4:17pm
2/22/2016 4:17pm
I've never seen a kicker reverse threaded before so I doubt it is. Are you able to get it nice and solid and not moving when you try to loosen it? Is the allen wrench grabbing tight or rounding it out? I suggest an allen T-handle, the kind with a small tip on the side of the handle that allows you to get good leverage. Or else cut it off like you said.
Andrew337
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Andrew337 2/23/2016 6:20am
2/23/2016 6:20am
Heat and penetrating oil should help, and so will the impact if it doesn't round out the allen head and spin.

Do you have a welder, or a buddy with a welder? You could weld a nut to the head of the bolt, just a few tacks from the inside of the nut to the bolt head. The heat will help free up the rusty threads and the nut will give you something to put a socket on and break it loose.
xnationalwrench 2/23/2016 6:40am
2/23/2016 6:40am
More than likely who ever put it on either cross threaded the bolt or used a air gun to install it or used red Loctite on it. Take your time and don't grab a hammer (even if you want to).
YZ125Ken
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YZ125Ken 2/23/2016 1:47pm
2/23/2016 1:47pm
I worked at it for hours today and could not get it to budge. I used a hand impact driver with no luck then even tried tapping on a torx head to try to get it to move. NOTHING! I even used the Dremel to cut some notches in the bolt to try a large screwdriver but to no avail.

The bolt is all frigging chewed up now!

I'm going to pick up an ezy out set tomorrow along with reversed drill bits. If that doesn't work, I guess I'm going to have to drill it out and hope not to damage the threads. I thought of using some heat but if heat the bolt head the bolt will expand. I need to get to the part where it's threaded into to engine. The onlky way to do that is to cut the kick lever off to access that area.

This has to be red locktited on! With the way the washer is bent in, I wouldn't be surprised if the previous owner not only used red loctite but impacted the bolt on as well.



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rallendude
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rallendude 2/23/2016 8:43pm
2/23/2016 8:43pm
I was going to suggest you NOT try the power tools on the allen bolt. But too late huh?

Take a grinder and grind the head off since it's ruined now. Pull the washer and the lever off then put some heat on the shaft and turn the screw out with vice grips. All else fails, you can remove the large clutch cover and take the whole stub shaft out and mount it in a vice.

Next time, take a piece of steel or brass and put against the head of the bolt and whack it hard with a hammer about six times. Then try to get it out. Heat is a good idea also but head the kick starter not the bolt.
Matt Fisher
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Matt Fisher 2/23/2016 9:07pm
2/23/2016 9:07pm
Cut the head off the bolt and then remove the shaft; easier to dork with in a vise than still in the bike. I wouldn't get too wound up over ruining the shaft, a new one is only about $70. You could probably find one on Ebay for about $20 shipped to you.
Paw Paw 271
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Paw Paw 271 2/24/2016 4:24am
2/24/2016 4:24am
Why not just remove the cover with the lever in place so you can work on it on the work bench?

Paw Paw
YZ125Ken
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YZ125Ken 2/24/2016 2:14pm
2/24/2016 2:14pm
I got it, fellas!!!! Bought an EZ-Out and drilled the hole out small to large. Tapped the turnout in and viola, bolt came loose! What a friggin relief!

Also got the new lever today but they did not send the washer or bolt! Just my luck!

Thanks to all for the suggestions and help!
sandman768
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sandman768 2/24/2016 2:16pm
2/24/2016 2:16pm
the sad part is, even if you get a brand new Suzuki kick starter, within about 30 kicks, it will be flopping around the same way as your old one! I steal my wife's hair scrunchies & just tie the kick start to the frame or pipe mount, it's like a strong rubber band, just pop it off the kick starter when you start it, you can also use cut strips of inner tube.

YZ125Ken
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YZ125Ken 2/24/2016 3:30pm
2/24/2016 3:30pm
Come on, Sandman, let an old fella bask in his glory for a bit!!! :-)
sandman768
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sandman768 2/24/2016 5:54pm
2/24/2016 5:54pm
YZ125Ken wrote:
Come on, Sandman, let an old fella bask in his glory for a bit!!! :-)
Just busting balls, I can relate to your pain, I just went through a similar situation with a seized brake caliper pin! Good job getting it done!
YZ125Ken
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YZ125Ken 2/25/2016 10:39am
2/25/2016 10:39am
Guys, one thing I wanted to ask. If you look at my photos above, there is a washer behind the attachment bolt on the kick lever. This washer is NOT SHOWN in any of the parts fiches I have come across. The washer has an indentation in it for the bolt head and I just cannot locate this part.

Does anyone know if maybe this washer was not supposed to be there in the first place? Any ideas at all where I could find a replacement for this or even just a part number?

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