2016 Kawasaki KX450F Won’t Kick Over!

MX208
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MX208
Edited Date/Time 10/17/2019 3:40pm
Hey all!

I’m having an issue with my KX450.

Last weekend, I went out riding. I stopped to take a break and when I went to kick it over to get going again, it made a loud backfire, shot my knee into the handlebar with a lot of compression and the Kickstarter seized up. I went to slowly kick it over again, and it freed up but it still very hard to even attempt to kick it over.
(It’s not completely seized up). I’m thinking it could be the auto decompression?

Thoughts? Thanks, and I appreciate everyone’s time.
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garagedog
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garagedog 10/17/2019 5:47pm
10/17/2019 5:47pm
Something is broken or cracked inside. Pull the clutch cover off and take a look.

The auto decompression is only felt right at TDC. Before and after should be easy movement.
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Paw Paw 271
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Paw Paw 271 10/17/2019 6:03pm
10/17/2019 6:03pm
Check to see if the cylinder is full of fuel. A faulty fuel injector will flood the cylinder and then you have a hydro locked engine. Also check the cam timing chain to be sure it has not jumped timing due to excess wear.

Paw Paw
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kb228
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kb228 10/18/2019 5:38am
10/18/2019 5:38am
Sounds like timing chain jumped
RGaede
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RGaede 10/18/2019 7:56am
10/18/2019 7:56am
If definatly could've skipped time, and if it did, do a letdown test to check for a bent valve. Also look at the right side center case very carefully. I would remove the inner clutch cover and inspect the area around the kickstarter. These bikes had reports of breaking the case around the kickstarter shaft when a large backfire would happen.
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Paul_Pitzonka
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Paul_Pitzonka 10/18/2019 10:54am
10/18/2019 10:54am
RGaede wrote:
If definatly could've skipped time, and if it did, do a letdown test to check for a bent valve. Also look at the right side center...
If definatly could've skipped time, and if it did, do a letdown test to check for a bent valve. Also look at the right side center case very carefully. I would remove the inner clutch cover and inspect the area around the kickstarter. These bikes had reports of breaking the case around the kickstarter shaft when a large backfire would happen.
I second this Have seen these bikes break the cases first hand
MX208
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MX208 10/29/2019 4:52pm
10/29/2019 4:52pm
It ended up being the timing chain. For some reason, the bike was a bit low on oil... and that may have caused the chain to jump.

How many hours until a top end rebuild? I’m wondering if I should do it, while I have it apart. I have 38 hours on it.

Thanks for everyone’s help!
kb228
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kb228 10/29/2019 5:17pm
10/29/2019 5:17pm Edited Date/Time 10/29/2019 5:18pm
The chain jumps because the tensioner is bad or the chain was worn. 38 hours isnt enough to make a chain stretch that far or for the guides to wear down, so it leads me to believe its a bad tensioner. Kawi is known for bad auto tensioners.

If it were my bike i would probably just be safe and do the timing chain and tensioner. If it happens again you can cause severe damage. Replacing both is cheap insurance.
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RGaede
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RGaede 10/29/2019 5:37pm
10/29/2019 5:37pm
Since it was low on oil, check the cam journals on the head. They like to wear out first when low on oil. If worn, check that the cam gears haven't slipped on the cams.
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MX208
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MX208 10/29/2019 6:32pm
10/29/2019 6:32pm
Thanks guys! I really appreciate your input. It helped a lot. I’m going to replace the chain and tensioner. I’ll also check up on the cam journals.
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