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Old 11-17-2013, 09:09 PM   #1
Robby1227
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Experience: 1-3 months

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2005 DR-Z400SM









DRZ kick start

Really just need to vent, posted on SMJ and TT as well.

Put on the kickstart, thought I had it all right, followed Mr Cobb's pics, put the backing plate in and everything. Thought I was good to go. Went to kick and it got stuck. Bumped it with the starter and it spun over but the kick start shaft moved as well and it sounded like a ratchet being spun. Pulled it all back down to find the spring out of it's seat in the case and this:

e7uvyje4

y7ata7us

Yes that is the backing plate that has been turned into a ring. I think I got all the chunks of aluminum out of the case. Can I put it back together and run it? I assume there is no way to make the kick start work in that case ever again.


If so maybe I'll just build up a dream motor with all the upgrades and the kickstart over the next year. Big bore, fcr, kickstart, wide ratio, stroker, cams, head work. Get a little excited just thinking about it.
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Old 11-17-2013, 10:40 PM   #2
hondarider77
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I've had some machine shops fix a damaged case. The gear that the starter motor turns on completely sheered out. The built up a big aluminum bead and drilled it out just enough for the pin that sits in the center of the gear. Maybe they could do something with your case. It's worth choking up the money for instead of buying a new motor.
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Old 11-18-2013, 08:40 PM   #3
Robby1227
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Well on the plus side she still runs fine. Got 98% of the aluminum out of the case and ripped the kick start off and it seems to be okay.


If anyone wrecks their DRZ I'd love to get a new motor and build it up.
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