Removing kickstarter lever.

htown16 · Feb 29, 2020

Always have a pia removing kickstarter lever. I try using a 2 jaw puller but it always slips off. Any suggestions?

rvich · Feb 29, 2020

I always take a large flat blade screw driver and tap it into the slot as a wedge to loosen its grip on the shaft and then slip it off.

Richard Tool · Feb 29, 2020

+1 on screwdriver to spread jaws .

batrider · Mar 1, 2020

Watch out not to go too far with the big screwdriver or you will have nice digs into your outer cover. Yup, I know this...

kommando · Mar 1, 2020

The screwdriver works but check the splines inside the kickstarter before you reinstall, as they are of softer steel they distort if the bolt has been loose, removing a few splines either side of the gap helps the bolt to keep a tight grip. The bolt needs to be hi tensile.

maylar · Mar 1, 2020

+2 on screwdriver wedge.

eskasteve · Mar 1, 2020

If you utilize the screwdriver wedge tip tap it towards the spline not the transmission case. Otherwise ,like Batrider, a screwdriver size gouge will mysteriously appear in your tranny outer cover. At that point you can always blame the marring on the PO.

Jdub · Mar 6, 2020

You can also use a threaded bolt and a stop washer in the cut to slowly screw the kickstarter "open." Hard to describe but hope you get the idea.

- OR -

Use the screwdriver driven towards the spline and when fully home, put some paper towels between the kickstarter and gearbox cover, then spray the splines with PB Blaster or similar, gently rocking the lever and rotating side to side to remove the packed in particulate in the splines. Removing is a gently rock rotationally while gently pulling straight off.

Good luck! Remember to use a brass brush to thoroughly clean those splines.

Dellis · Mar 24, 2020

Jdub said:
You can also use a threaded bolt and a stop washer in the cut to slowly screw the kickstarter "open." Hard to describe but hope you get the idea.

I take it you mean put the stop washer in the gap and wind the bolt in from the opposite side to where the bolt normally mounts? If so this is the best method by far.

Dave

fiatfan · Mar 25, 2020

Jdub said:
You can also use a threaded bolt and a stop washer in the cut to slowly screw the kickstarter "open." Hard to describe but hope you get the idea.

- OR -

Use the screwdriver driven towards the spline and when fully home, put some paper towels between the kickstarter and gearbox cover, then spray the splines with PB Blaster or similar, gently rocking the lever and rotating side to side to remove the packed in particulate in the splines. Removing is a gently rock rotationally while gently pulling straight off.

Good luck! Remember to use a brass brush to thoroughly clean those splines.

That idea with the bolt is the best tip I´ve seen in a long time!