• 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 The previous version was outdated and no longer supported.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!

250-500cc Kickstart lever

B

Bart

Husqvarna
AA Class
my kickstart lever failed today, it's locked in close position even though I kept it regularly greased.
So is there an after-market upgrade lever, something that's a bit more ergonomic, lighter and more durable? Perhaps a switch over from a other make?
 
I don't think there is any other kicker for the 250/300 bikes. The position of the kicker is so weird, they have to put a big bend in the lever to clear the pipe, and make it a very strange shape compared to kickers on virtually every other bike. I think you're stuck with the stocker. Maybe peel away the rubber boot and get some penetrating oil in there to loosen it all up?
 
I'd give it a shot with soaking it real good with some WD 40... That stuff is pretty good at freeing frozen parts up...
 
Take off circlip on bottom, knock pin out then lever will come off. You will find a ball bearing jumps out and the spring behind it is worn/plugged ect. You can take out ball bearing and it all works again but swings in and out. I'm going to try a spring to get it to return as that ball bearing system keeps locking when it all get worn enough.
 
i had the same problem. i dismantled and filed off some damage around the indentation where the bearing sits. works fine now
 
Well it's been a while, did all the things posted above, before posting this topic.
Anyway I got it sorted, it was actually worn in to deep therefore the ball didn't engage anymore.
I welded up the hole, made a new one (not that deep of course), and placed some shims to take up the slack/play in the lever.
It's functioning better then it ever has!

First I thought the cast steel (iron?) wouldn't be weldeable but it did the trick (TIG, with steel rod).
 
I took mine apart, cleaned and greased it but with the first flick of the lever the ball actually comes out or it just locks up. How do you get the ball to stay in place? It doesn't appear to be attached in any way. I am contemplating taking the ball out and just using an old inner tube piece to hold it in. Third world class I know. I'm open to help.
 
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