125 2001 YZ125

2strokesteve89

2strokesteve89

Trfsrfr:
I told him (for the 10th time) "when we got to the track today, you TAP the lever down with your toes, not STOMP it down with your foot."
Okay Dad.
Pretty sure the shaft is good, but I'll take another look tomorrow. Got the new MX33 to deal with right now.
Thanks BigDan!
Click to expand...

DAN is correct, that shaft may look good, but I've gone thru the same exact problem on my RM, replace the shaft with the lever.
 
Trfsrfr

Trfsrfr

2strokesteve89:
DAN is correct, that shaft may look good, but I've gone thru the same exact problem on my RM, replace the shaft with the lever.
Click to expand...
Thanks Steve, I appreciate that advice, and you're also one of the reasons this site is my home page, NO HOMO DAN!
But I just ordered the steel lever from eBay and of course I'm gonna install it first and see if it works...:noidea:
 
Trfsrfr

Trfsrfr

Redordead89:
Now tell the kid again to stop stomping it or it will be the box in bits next :banghead:
Click to expand...
Oh he knows. But if the shaft is worn it's not entirely his fault.
Next one is all steel on steel though, so I think he'll be okay. He better be anyway.

But that and my yz's chain adjuster problem puts the kabash on us hitting the track tomorrow. We were gonna go to a different track, the only one thats open during the week, and I was gonna let him put his money where his mouth is...
It'll have to wait til the following weekend I guess.
 
Trfsrfr

Trfsrfr

Okay, so this is weird.
I have no idea why this is happening.
I replaced the shift shaft and lever, and had the kid go to kick it over and take it for a test ride, and the kickstart shaft doesn't kick back, and was binding up. No problem I thought, I figured I missed the spring tang again. Pulled it apart and the tang was in the notch.
After some checking I find that the shaft is broke;
Kickstart Shaft Broken.jpg
So I order a new one. New shaft shows up, and again it binds up.
I've had this thing in and out and the cover on and off at least 20 times in the last week. I've tried every configuration possible, including putting the plastic spring retainer and washer in backwards, and it still binds up when torqued.
And it doesn't just bind up on the return to normal position, it binds up on the downward kick.
Another shout out thanks to @PALMER84ONE for the timely tech help!
But it still binds when fully torqued.
But I did find that if I left one bolt loose, the one directly under the kickstart lever, it would allow it to spring back, but I cannot for the life of me determine why.
I thought maybe the gasket was bad, nope, maybe something was obstructing (like the return spring) nope.
Weird for sure, especially since I never had an issue until I took it apart, worked fine for the last 8-9 months.

Left the bolt under the lever a little loose, kid took it around the block tonight and it runs like it should...
:noidea:
 
Mihylo33

Mihylo33

Trfsrfr:
Okay, so this is weird.
I have no idea why this is happening.
I replaced the shift shaft and lever, and had the kid go to kick it over and take it for a test ride, and the kickstart shaft doesn't kick back, and was binding up. No problem I thought, I figured I missed the spring tang again. Pulled it apart and the tang was in the notch.
After some checking I find that the shaft is broke;
View attachment 32295
So I order a new one. New shaft shows up, and again it binds up.
I've had this thing in and out and the cover on and off at least 20 times in the last week. I've tried every configuration possible, including putting the plastic spring retainer and washer in backwards, and it still binds up when torqued.
And it doesn't just bind up on the return to normal position, it binds up on the downward kick.
Another shout out thanks to @PALMER84ONE for the timely tech help!
But it still binds when fully torqued.
But I did find that if I left one bolt loose, the one directly under the kickstart lever, it would allow it to spring back, but I cannot for the life of me determine why.
I thought maybe the gasket was bad, nope, maybe something was obstructing (like the return spring) nope.
Weird for sure, especially since I never had an issue until I took it apart, worked fine for the last 8-9 months.

Left the bolt under the lever a little loose, kid took it around the block tonight and it runs like it should...
:noidea:
Click to expand...


Sounds like one of these parts is missing, bent or broken.
https://www.rockymountainatvmc.com/oem-schematic/3
88D11148-E514-41EE-93B1-DC0EC31F1951.jpeg
 
Trfsrfr

Trfsrfr

I thought so too, but thats not the case.
And someone please do me a favor and tell me what that Kick gear clip does? Number 6 in the above pic.
I cannot see any reason for it. Its a gall bladder.
 
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Mihylo33

Mihylo33

Trfsrfr:
I thought so too, but thats not the case.
And someone please do me a favor and tell me what that Kick gear clip does?
I cannot see any reason for it.
Click to expand...

Keeps the gear in place.
If you didn’t replace everything in that diagram then there is your problem. Whenever I have had an issue with trans or something like this I replace every clip bushing and bearing with it. It was a lesson hard learned because I tried to save $5 on a bushing and circlip once and it cost me an additional $800 imparts and a race win. I might have a picture of the damage somewhere. I kept the $800 in stripped gears to remind me of how I tried to cheap out.
 
PALMER84ONE

PALMER84ONE

90% 0f the time on the kicker, it is the shaft itself. However, there are measurements and specs in the book on number 6 and if it is not in spec, it's binding. Also, take a look on the inside of the cover for any witness marks from the bad shaft you pulled out, as it needs to be flush, clean, and may need to be filed.
 
Trfsrfr

Trfsrfr

I looked for marks but didn't see anything, and the shaft is brand new.
I seriously looked at everything, like 20 times. Didn't see anything out of the ordinary.
As long as that one cover bolt thats not as tight as it should be doesn't leak or cause any other problems I'll run it.
 
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