125-200cc Kick start shaft failure

My buddy Jon has broken his kick start shaft for the second time. He has a hefty leg for sure but any ideas on why this is happening? Anyone else break the kick start shaft on a Husky 125? Help with your thoughts is appreciated.

PS, He is kicking a 165 so a new kick starter from Motosportz would be appreciated.....hint....hint

I saw Kelly break one... Seems like mine is getting loosey goosey....

Yes, we NEED a longer, stronger option for the 165

Matt,

His spline shaft is breaking right at the case where there is a machined indent.

Oh the joys of exceeding design specifications.

I wore out a kick start lever on my '02, but this is the first shaft I remember hearing about breaking.

I think you are probably right. He was also experiencing problems with the kick starter not engaging and kicking against no resistance which would make that worse when the lever impacts the peg and he puts a side torque on the shaft.

I broke my 2008 CR125 kicker last weekend. It was the lever, around where the boss inserts into it. Cracked in half. Replacing it is expensive for me, since I decided to replace the whole kick assembly as well as everything that attaches to it (read: ordered a new 2012 WR 125!)

Yeah I hear BMW charges about $5,999.00 for them kick levers! Damn them!

A longer kick starter would be a huge plus! Thank goodness my size 13s don't take much boot to fire the 165 up !

Haha, your lucky!!! I wear a 14! Hard to find boots!

Nice Dave!

Wouldn't a longer kick starter put more load on the shaft?

ahhhhh bugger, i just did this yesterday as well...
my bike is still in the bush, in the naughty corner.

what is involved in the replacement of kicker shaft?
split the cases???

never broke one and I feel hard to believe that it would happen on a 125 or a 165

wrong technique I would say

try to start a CR 500

it will not break the shaft but your leg if you are unlucky

did kick for a while a a XR 650, no thank you

have now a CRF 450 with shitty battery, I only swear if it is not firing up after 4 kicks

the WB 165
its not starting with your hand as the 125 trim did but intimidating or breaking is very far from that.

Robert-Jan

You will need to remove the clutch side case but not split the engine cases. It is also much easier if you remove the clutch to get the kick start gear out. I feel your pain.

That's a pretty substantial shaft to be shearing off like that. My guess is bad heat treating. Either that or they are using a MIM part instead of a forging.

bahahaha, are you kidding???
a metal shaft shouldn't just break due to poor technique...
if so why didn't it break 100hrs ago when the bike was brand new?
poor metal quality by the looks of it.
lol.