2004 KX500 Kickstarter/other Help

Mechanical problems discussed for Dirt Bikes and Dual Sport Bikes
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jason93
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Joined: Mon Nov 12, 2018 3:55 pm

2004 KX500 Kickstarter/other Help

Post by jason93 » Sun May 05, 2019 1:45 am

I’m hoping you guys can help narrow my path on this Kickstarter issue I got today on one of my kx500s. My 04 is a nice tight motor and runs great, I went to a practice track today did 8 laps to learn the track and had arm pump so I pulled off to take a break. As I drove back to the stand the bike let out a really odd backfire/pop. So I take 20 minutes then go to start the bike and when I kick down the Kickstarter doesn’t return, and it’s not hanging on the foot peg. I can take my foot and lift it up. It’s not slipping just goes down and won’t return.

Normally I’d think it was the return spring but now I’m thinking it may be lower end or something else because the bike hasnt started since that pop. Figured I’d ask here before I tear into it. I’ll look at it again tomorrow and see what I find. Any ideas?

Much appreciated.

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Sandblaster
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Joined: Thu Jun 07, 2012 3:50 pm
Location: Eugene, OR
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Re: 2004 KX500 Kickstarter/other Help

Post by Sandblaster » Sun May 05, 2019 2:34 am

Sounds to me that you have two issues.
A broke return spring and a electrical issue,
But what electrical issue?
Almost sounds like a sheared flywheel key.
But start simple... fix the return spring,
Then disconnect the kill switch and try to start it.
Then, replace the plug...
If it is sparking good check that key...
Post what you find..
If bikes are for kids I'll never grow up.

jason93
Posts: 6
Joined: Mon Nov 12, 2018 3:55 pm

Re: 2004 KX500 Kickstarter/other Help

Post by jason93 » Sun May 05, 2019 3:14 am

Thank you Sandblaster, I will try this in the morning. Many thanks.

jason93
Posts: 6
Joined: Mon Nov 12, 2018 3:55 pm

Re: 2004 KX500 Kickstarter/other Help

Post by jason93 » Mon May 06, 2019 7:13 pm

You were right... keyway sheared off. Wow these keyways are really small compared to the Honda 500. I think some lapping is in order. Sandblaster, thank you again so much for the info l, super helpful and spot on with the diagnosis.

Many thanks.

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Sandblaster
Posts: 5880
Joined: Thu Jun 07, 2012 3:50 pm
Location: Eugene, OR
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Re: 2004 KX500 Kickstarter/other Help

Post by Sandblaster » Tue May 07, 2019 6:43 am

Sometimes I get lucky :lol:
If bikes are for kids I'll never grow up.

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