Can't get KTM kickstarter off -- Wassup?
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Thread: Can't get KTM kickstarter off -- Wassup?

  1. #1
    Join Date
    Nov 2005
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    Mason, Michigan
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    1,225

    Default Can't get KTM kickstarter off -- Wassup?

    I have a 525 KTM and the allen head bolt that holds the kickstarter to the shaft won't budge. This is the bolt that seems to screw through the kickstarter and into the end of the shaft. It makes me think it might be reverse threaded so it won't back off when kickstarting. I'm not sure which way to turn it, and anyhow it won't budge, even with a lot of force, in either direction.
    Also, while I'm at it, does anyone know the torque setting for the bolts holding on the clutch cover.
    Thanks for any help.

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  3. #2
    Join Date
    Oct 2004
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    Meriden, CT
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    Get your torch out and heat it a bit, the loctitie maybe Red
    2006 KTM560SMR #67
    2009 KTM250SX
    2002 Montesa 315r COTA
    LRRS #167
    http://www.decalmx.com/

  4. #3
    Join Date
    Oct 2006
    Location
    Ogden, UT
    Posts
    47

    Default 2nd that

    Red loctite is basically a must on KTM kickstarters, because they were designed to randomly fall off in the woods (often a day before a big snowfall).

    And it is regular threaded.

    Get out the propane and heat it up a bit, loosen by tapping on your wrench.

    take care

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  6. #4
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    Default

    Okay, thanks. I'll try that tomorrow when I get time.

  7. #5
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    Aug 2004
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    Snohomish, WA
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    Default

    Get a high quality allen that connects to a ratchet and put a 6" extension on it and give it a smack with a hammer then try and remove it.

    Most people have the opposite issue, the kick starter falls off...

  8. #6
    Join Date
    Oct 2004
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    Yeah after seeing a few fall off at the track I aways loctite and check mine.
    2006 KTM560SMR #67
    2009 KTM250SX
    2002 Montesa 315r COTA
    LRRS #167
    http://www.decalmx.com/

  9. #7
    Join Date
    Nov 2005
    Location
    Mason, Michigan
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    Default

    Okay, guys. Thank you. Heating it up a bit then reefing on it worked.

  10. #8
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    Aug 2004
    Location
    Florida
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    Also Loctite your shift lever. My came loose during a race last month.
    Mike

  11. #9
    Join Date
    Nov 2005
    Location
    Mason, Michigan
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    Default

    What about the torque setting for the 8 mm bolts holding the clutch cover on? Does anyone know what it is? If I don't hear from anyone, I'll go with 6 lbs and see if that holds the oil in.

    p.s. If anyone wants to know where to get an inch-pound torque wrench for $40, I just got one from American Eagle Superstore in Lansing, Mich. Sure it's from China or some place like that, but it works fine and beats Sears Craftsman's torque wrench at $200. This wrench goes from 0 to 200 inch pounds and is a foot long, comes in a case, and is the type whose handle "breaks" when it reaches the setting. Also, it shows metric settings. Maybe American Eagle has a website, if you want one.

    Okay, who knows the torque setting for those KTM clutch cover bolts please?

  12. #10
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    Florida
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    Here you go...

    Mike

  13. #11
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    Nov 2005
    Location
    Mason, Michigan
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    Thank you, and there's the kickstarte allen bolt setting that I'll be needing. This is a great forum with great people. Thanks again.

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