1. Husqvarna Motorcycles Made In Sweden - About 1988 and older

84 KIckshaft Issue

Discussion in 'Vintage/Left Kickers' started by Dwarf66, Dec 25, 2018.

  1. Dwarf66 Husqvarna
    AA Class

    Location:
    CT
    Husqvarna Motorcycle:
    79 250OR 84 250WR 87 510 TE
    Other Motorcycles:
    78.5 RM250C-2 82 PE175Z
    I have to replace the kickshaft on my 84 250WR. Large spline. The kicklever just barely fits on. Very tight fit. Is this normal due to inconsistent machining? This is a very lightly used part. Seems like I have to relieve the shaft splines as they are slightly larger.
    On a side note does anyone have 1 clutch cover dowel they can spare?
    Thanks boys.
    Dwarf66, Dec 25, 2018
    #1

  2. husky jim Husqvarna
    Pro Class

    Location:
    USA
    Husqvarna Motorcycle:
    14 WR300, 87 430wr, 86 430ae, Tr650

    I have spare '85 cover that is rotted at the water pump I can steal a pin from. What's your address ? I'll mail it you tomorrow or Thursday!
    husky jim, Dec 25, 2018
    #2

  3. jimspac Husqvarna
    Pro Class

    Location:
    Connecticut
    Husqvarna Motorcycle:
    82 250WR, 82 430WR, 84 250WR, 85 400
    Other Motorcycles:
    86 400WR, 82 Montesa Cota 349
    The kickstart lever fitting would indicate the shaft was at the high limit during the manufacturing process
    jimspac, Dec 25, 2018
    #3

  4. DeathFromAbove My Cat Says AREAR!

    Location:
    North New Jersey
    Husqvarna Motorcycle:
    70,71 360 8s 72,74 450 73 360 73 250
    Other Motorcycles:
    66 Triumph Trophy 99 ZRX1100
    Over time the lever/spline contact will loosen up. Clean both splines lever and shaft with solvent and a wire brush. It will never get tighter than it is now!
    DeathFromAbove, Dec 25, 2018
    #4
    justintendo likes this.

  5. suprize Husqvarna
    Pro Class

    Location:
    Bendigo, Australia
    Husqvarna Motorcycle:
    WR 400, bike in a box Moto Villa 350
    Other Motorcycles:
    ktm 300
    check for any burrs or slightly extruding steel on the splines that may be causing the issue
    suprize, Jan 5, 2019
    #5
    DeathFromAbove likes this.

  6. DeathFromAbove My Cat Says AREAR!

    Location:
    North New Jersey
    Husqvarna Motorcycle:
    70,71 360 8s 72,74 450 73 360 73 250
    Other Motorcycles:
    66 Triumph Trophy 99 ZRX1100
    Have any pics?
    DeathFromAbove, Jan 5, 2019
    #6

  7. ruwfo Administrator

    Location:
    NJ
    Husqvarna Motorcycle:
    1980 390CR, 1982 430CR, 1984 400WR
    Other Motorcycles:
    1985 250XC, 2016 FJ-09
    Jim is 100% correct, and yes a little on the tight side is better..

    The 1984 Husky's were recalled for the kicker shaft snapping off right were the lever almost touches the side case.
    ruwfo, Jan 9, 2019
    #7