[steve1979]

What a day, way out riding in the middle of nowhere, literally. Over huge hills, through marshy bogs etc when the bike conked out in the middle of nowhere about as far from civilization as possible in Shetland. Engine just died and refused to start (stator problems) i think and to top it off with all the kicking on the kick starter the bugger snapped off and took a big chunk out of my carbon lookalike frame protector at the same time, BIG BOO eventually got the bike bump started just as it started to rain.

What a day. Still no point in getting mad about it lol

[RichT]

What model do you have and which part of it sheared?

unfortunately you may get mad about it when find out how much the parts cost!

[steve1979]

Hey Rich T, ha ha yes there not cheap, how ever i am ! lol no seriously for the short term i may get it welded until i can get a new one ordered, i think they retail around the £120 mark, bit of a bummer as i could have put that money to something more useful like getting my stator rewound, Still there are more serious things in life to get upset about, i'm trying to find a parts list as the spring and ball bearing upper washer and both O rings have disappeared, i never thought to look amongst the heather for those bits, i have to laugh about it now, it all went silent when the kick start snapped off i think my pals were expecting me to blow a fuse

I have a 2003 txt pro 250 which i get the mickey taken because it's usually so clean, funny how i'm probably the fussiest one with my bike maintenance yet i'm the one who gets all the problems.

I noticed as i was kicking her over the kick start was getting stiffer than normal to turn out 90 degrees to put your foot on then all of a sudden it went with a ping and landed on the ground it sheared of right in the middle where it pivots around the splined shaft if you know where i am, so the bottom half is still attached and top half came away, i wasn't violently jabbing at it but it always decked out on the foot peg and i assumed that was normal, maybe with 7 years worth of kicking and crashes it's had a hairline fracture

[wri5hty]

£120 gets you all the kick start ( everything that goes onto the shaft ). reason i know this is me and my mate both have 2004 300 gas gas's and both broke them at the same trial in the same day. whats the chances eh.

[RichT]

Steve1979, You are a calm chap!

There are parts catalogues to download on 'trialspartsusa' or have a look at 'haventrialsport' they list everything with prices.
The arm is only available as a complete assembly but the other parts are available individually! Why?
You can weld it till you get another then keep it as a spare.

I have seen a few break off and its usually when the arm has turned out and the bike falls on that side and the rider went some where else.

[JSE]

RichT, on Jul 4 2010, 02:53 PM, said:

I have seen a few break off and its usually when the arm has turned out and the bike falls on that side and the rider went some where else.

I've also seen a couple of them snap when the capscrew through the bushing is allowed to get loose. That over-stresses the lower part of the lever
by spreading the machined tabs on the bottom of the lever that pivot on the bushing. I always advise Loctite on the capscrew and use a little
lube on the bushing/tab area now and then.

Jon

[steve1979]

Thanks guy's, that's excactly what happened the top cap had come off i think as it was missing, and it's broken where you described. Probably my fault as i took it apart a while ago to replace one of the o rings and lube it all up. so it's probably worked it's self loose