• 2 Stroke Husqvarna Motorcycles Made In Italy - About 1989 to 2014
     WR = 2st Enduro & CR = 2st Cross

  • Hi everyone,

    As you all know, Coffee (Dean) passed away a couple of years ago. I am Dean's ex-wife's husband and happen to have spent my career in tech. Over the years, I occasionally helped Dean with various tech issues.

    When he passed, I worked with his kids to gather the necessary credentials to keep this site running. Since then (and for however long they worked with Coffee), Woodschick and Dirtdame have been maintaining the site and covering the costs. Without their hard work and financial support, CafeHusky would have been lost.

    Over the past couple of weeks, I’ve been working to migrate the site to a free cloud compute instance so that Woodschick and Dirtdame no longer have to fund it. At the same time, I’ve updated the site to a current version of XenForo (the discussion software it runs on). The previous version was outdated and no longer supported.

    Unfortunately, the new software version doesn’t support importing the old site’s styles, so for now, you’ll see the XenForo default style. This may change over time.

    Coffee didn’t document the work he did on the site, so I’ve been digging through the old setup to understand how everything was running. There may still be things I’ve missed. One known issue is that email functionality is not yet working on the new site, but I hope to resolve this over time.

    Thanks for your patience and support!

125-200cc Kick start shaft failure

wallybean

wallybean

Mini-Sponsor
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.
 
Is the spline shaft breaking or the long shaft portion of the kick lever? If it is the long shaft portion, my guess is the shaft is get chunked when it hits the foot peg. After it gets notched enough, then it breaks at that location.
 
I saw Kelly break one... Seems like mine is getting loosey goosey....

Yes, we NEED a longer, stronger option for the 165
 
MattR said:
Is the spline shaft breaking or the long shaft portion of the kick lever? If it is the long shaft portion, my guess is the shaft is get chunked when it hits the foot peg. After it gets notched enough, then it breaks at that location.
Click to expand...

Matt,

His spline shaft is breaking right at the case where there is a machined indent.
 
wallybean said:
Matt,

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

Wow, he has a serious kicking leg!

Since the shaft is free to rotate, I can only guess that he is also putting some lateral load as he kicks the lever. For example, instead of kicking straight backwards, he is kicking slightly on an angle away from the bike. This would put some bending load onto the shaft.
 
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!)
 
dfeckel said:
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!)
Click to expand...
Yeah I hear BMW charges about $5,999.00 for them kick levers! Damn them! :D
 
dfeckel said:
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!)
Click to expand...
Nice Dave!
 
wallybean said:
Matt,

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


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???

:banghead:
 
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.
 
R-J van Hulst said:
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
Click to expand...


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.
 
You must log in or register to reply here.
Back
Top