How to Fix Stuck Kick-Start on Your Dirt Bike

A stuck kick-start is undoubtedly frustrating, especially before embarking on a big off-road trip. Fortunately, this guide has got you covered on how to navigate this predicament, ensuring you’re well-prepared for any kick-start challenges that come your way.

Depending on the root cause, fixing a stuck kick-start involves cleaning, adjusting, or replacing damaged components. Following this, it is essential to be strict with maintenance. Whichever the culprit, the approach to resolving this issue on 2-strokes and 4-strokes is the same.

If you haven’t already, check out my previous article on the causes of a stuck kick-start.

Solutions

Your dirt bike’s service manual is still the best resource for addressing issues with the kick-starter assembly. But if you’re looking for a quick reference, you may refer to the general guidelines and quick assessment checklists (QAC) below:

Tools Required:

• Brush or compressed air for cleaning
• High-quality lubricant appropriate for your dirt bike
• Rust remover like WD-40 Specialist Rust Remover Soak, One Gallon (view on Amazon)
• Polishing materials
• Rust inhibitor and anti-corrosion agent
• Wrenches and socket set
• Socket and ratchet set
• Allen wrenches
• Pliers
• Feeler gauges
• Torque wrench
• Rubber mallet or soft hammer
• Calipers (for checking alignment tolerances)
• Cable tension gauge
• Multimeter
• Spark plug socket, gap tool, and wire puller
• Ignition timing light
• Dielectric grease
• Compression tester
• Replacement gears, return spring, kick-start lever, etc.

Dirt and Grime Accumulation

Cleaning:

• Use a suitable brush to remove visible dirt and grime from the kick-start mechanism.
• Apply a gentle cleaner to dissolve stubborn deposits.
• Ensure thorough cleaning around pivotal points and gears.
• Depending on the severity of dirt accumulation, disassemble the kick-start mechanism (for more thorough cleaning).
• Check the seals and bearings around the kick-start mechanism for signs of dirt ingress and replace damaged parts as needed.
• Ensure components are thoroughly dried before reassembly.

Lack of Lubrication

Lubrication:

• Identify lubrication points in the kick-start assembly.
• Check for signs of wear on moving parts (replace if significant).
• Use a high-quality lubricant to coat moving parts.
• Ensure even distribution of lubricant, preventing future friction. Rotate the kick-starter several times after applying lubricant to ensure it spreads evenly and reaches all critical points.
• Wipe off excess lubricant to prevent dirt and debris.
• Implement a regular maintenance schedule for lubricating the kick-starter.

Corrosion

Cleaning and Rust Removal:

• Before addressing corrosion, inspect the kick-start components for any underlying damage.
• Disassemble affected components for thorough cleaning (if necessary).
• Gently clean the affected areas with a rust remover.
• Polish the kick-start shaft and gears to remove corrosion.
• While disassembled, check the seals and bearings around the kick-start mechanism for signs of wear or damage and replace them as needed.
• Apply a rust inhibitor before an anti-corrosion agent for protection.
• After cleaning, applying anti-corrosion agents, and replacing any necessary parts, reassemble the kick-start mechanism. Test its operation to ensure smooth functionality.

Worn-out Kick-start Gears

Replacement:

• Disassemble the kick-start assembly.
• Thoroughly inspect all gears for wear and tear. Include adjacent components that interact with the gears, such as the idler gear and kick-start shaft.
• Replace worn-out gears with new, compatible ones. Do the same with adjacent components.
• Before reassembling the kick-start assembly, apply a suitable lubricant to ensure smooth operation of gears and associated components.
• After reassembling the kick-start assembly, do a comprehensive test to confirm correct engagement and ensure smooth operation.

Damaged Kick-start Return Spring

Spring Replacement:

• Disassemble the kick-start assembly to access the damaged return spring and evaluate its condition.
• Locate the damaged return spring and assess the extent of damage.
• While addressing the damaged spring, inspect the surrounding components for any wear, damage, or misalignment that might have contributed to the spring issue.
• Replace the spring with a new, compatible one, ensuring proper alignment and installation.
• Before reassembly, apply a suitable lubricant to the kick-start mechanism to ensure smooth operation and reduce friction on moving parts.
• Thoroughly test the kick-start mechanism after reassembly. Verify that the kick-start lever recoils as expected.

Kick-Start Lever Bending or Misalignment

Adjustment or Replacement:

• Visually inspect the kick-start lever for any signs of misalignment or bending. Check for irregularities in its movement.
• Adjust the lever for proper alignment.
• Evaluate the extent of damage. If misalignment or bending is severe, consider replacing the lever.
• While addressing the kick-start lever, inspect surrounding components for any wear, damage, or misalignment that might have contributed to the issue.

Idler Gear Displacement

Repositioning:

• Remove the kick-start lever and any covers that provide access to the kick-start mechanism.
• Check the idler gear for wear, damage, or any signs of misalignment. Examine adjacent components, including the kick-start shaft and associated gears, for any issues.
• Carefully realign the idler gear to its proper position. Pay attention to gear teeth engagement.
• Assess the idler gear and surrounding components for any damage that may have led to the displacement. Replace damaged parts as necessary.
• Ensure secure fastening to prevent future displacement.
• Apply lubrication to the idler gear and other moving parts before reassembly.
• Perform a thorough test of the kick-starter mechanism.

Clutch Drag

Clutch Inspection:

• Examine the clutch plates for wear. Look for discoloration, warping, or uneven surfaces.
• Adjust the clutch cable to spec.
• Check other clutch assembly components, such as the pressure plate, release mechanism, and springs, for wear or damage. If detected during inspection, replace the worn-out component with new, compatible ones.
• Confirm that the clutch lever operates smoothly and returns to its resting position without resistance.
• Inspect the clutch cable and lever for any signs of binding or restriction. Make sure to address any issues found.
• Examine the clutch basket and hub for wear, grooves, or damage.
• Verify that the clutch lever has an appropriate amount of free play according to the OEM recommendations.

Engine Issues

Diagnosis:

• Inspect the engine for irregularities like visible damage, oil leaks, unusual sounds, or any signs of overheating.
• Examine the spark plug and ignition system to ensure proper combustion. Clean or replace the spark plug if needed.
• Inspect the fuel system, including the carburetor or fuel injection components, for blockages, leaks, or improper fuel delivery.
• Check the air filter and intake system for cleanliness and proper airflow. If necessary, replace or clean the air filter.
• Measure engine compression to ensure it falls within the manufacturer’s specified range.
• Inspect and adjust the valve clearance according to the OEM specs.
• Verify the timing and tension of the cam chain.
• Examine electrical components such as the stator, regulator-rectifier, and wiring for any faults or damage.
• Check the oil level and make sure it’s within the recommended range.
• Inspect the cooling system, including the radiator and coolant levels, to prevent engine overheating.
• Address any identified engine issues.
• Ensure the engine is in proper working condition and without any abnormal symptoms.

Malfunctioning Decompression System

Decompression System Check:

• Inspect the decompression system components for malfunctions, including the lever, cable, and associated mechanisms.
• Pinpoint the specific issue. Check for frayed cables, damaged levers, or any decompression system abnormalities.
• Undertake necessary steps to repair or replace damaged components. This may involve replacing worn cables, fixing a damaged lever, or addressing other issues affecting the decompression mechanism.
• Replace irreparable parts with new, compatible ones to ensure the proper functioning of the decompression system.
• Verify the decompression cable is properly tensioned to allow smooth and effective operation of the decompression mechanism.
• After repairs or replacements, thoroughly test the decompression system to ensure it functions as intended.

Tips for Kick-Start Maintenance

Recommended Intervals (Varies)

The recommended maintenance intervals for kick-start upkeep on a dirt bike can vary depending on riding conditions, frequency of use, and environmental exposure. But as a general guideline, veteran revheads strongly suggest the below intervals:

After Each Ride

• Perform a quick visual inspection.
• Wipe down visible dirt and debris.
• Check for any wear or damage.

Weekly

• Conduct a more detailed cleaning session.
• Inspect pivotal points, gears, and the kick-start mechanism.
• Apply lubricant to moving parts.
• Check for loose fasteners.

Monthly

• Remove the kick-start lever for a thorough inspection.
• Clean and lubricate the kick-start shaft.
• Inspect the return spring for any signs of damage.
• Check for any misalignment or bending of the kick-start lever.

Every 3-6 Months

• Disassemble the kick-start assembly for a comprehensive cleaning.
• Inspect gears, shafts, and other components for wear.
• Replace lubricant and ensure even distribution.
• Check for corrosion on metal surfaces.
• Verify the condition of the kick-start return spring.

Annually

• Replace the kick-start return spring if it shows signs of wear.
• Inspect and replace any worn-out gears or components.
• Check for any changes in the kick-start lever alignment.
• Verify the condition of seals and bearings.

Inspection (Frequency: Before and after every ride!)

Inspect kick-starter components for excessive play, rust, or wear, and include spring tension in your inspection when you can. If you notice any telltale signs in the preceding section, immediately do diagnostics and address the identified culprit. Doing this is crucial to ensure you avoid kick-starting irregularities on the road.

Cleaning (Frequency: Every 10—15 hours)

Although this is the general recommendation, this frequency can vary based on riding conditions. More frequent cleaning may be necessary in particularly dusty or muddy environments, potentially after each ride.

Regular visual inspections can help riders gauge the need for cleaning, ensuring that the kick-starter remains free of dirt, grime, and contaminants that could compromise its functionality.

Lubrication (Frequency: Every 10—20 hours)

Lubricating a dirt bike kick-starter follows a frequency akin to cleaning. However, variations depend on riding conditions, climate, and lubricant type. Frequent lubrication is crucial for optimal performance and wear protection in harsher or wetter environments.

Relative to this, regular visual inspections, attention to any signs of increased friction or stiffness during kick-starting, and the use of high-quality, dirt-resistant lubricants suitable for motorcycle kick-start mechanisms are paramount.

Conclusion

Understanding the root causes is crucial to addressing the dirt bike kick-start getting stuck. However, prioritizing preventive measures is key.

A routine of thorough inspections, cleaning, and lubrication never fails to significantly reduce the risk of kick-start problems. Opting for high-quality products and tailoring maintenance to riding conditions will keep your dirt bike kick-starter performing at its best — ensuring you uninterrupted off-road thrills.