Bent kick start shaft?

1978 Twin that has been idle for 12 years (notice the mold on the grips) . Just got the engine unstuck but the kick start will not return upright. I pulled the cover and it was hard to get off. The shaft does not look centered for the cover hole and when I actuate the shaft with the kick pedal the shaft swings in a small arc. I can't believe the shaft would be bent as the pedal and cover look fine. Is the shaft maybe not installed or seated properly? Can I pull the shaft without messing up the gear and ratchet mechanism? Thanks. [attachment=113040]20171105_133429.jpg

You have to split the engine case.

Hi,

I#m running two Z 750 twins and I can confirm that you might have bent the kickstarter shaft to a runout of about 1 mm just by kicking the twin engine



To improve the situation I have installed a shaft with increased strength



Martin

Unbelievable that a tempered shaft can bent by kicking a twin engine.
Must be a faulty construction. Is the new shaft a new stronger revision by Kawasaki?

Thanks for the response. I believe it is bent now. I put in a new seal (old one was damaged) and it seemed to help but I still have to lift the pedal a bit before it returns. Oh well, hopefully not going to be kick starting it much.

The kick starters were for emergencies. I'm shocked at the weakness of the one pictured. Too bad they did away with them. The smaller fours all seem to have weak starter clutches and are hard to get to.
Steve

Scirocco wrote: Unbelievable that a tempered shaft can bent by kicking a twin engine.
Must be a faulty construction. Is the new shaft a new stronger revision by Kawasaki?

If material stresses from use are overseeding material stress limits also a tempered material will plastifie and the shaft will bent. The new shaft isn't Kawasaki oem, I had it made by a prototype workshop.

The good news is that you can also straighten a bent shaft.

In one of my twins I have removed the starter Motor and clutch. So following SWest's argumentation each start of the engine is an emergency start now. But it's working!

SWest wrote: ... The smaller fours all seem to have weak starter clutches and are hard to get to.
Steve

Make that the 650-based fours (650/700/750). The 400/500/550 fours very, very rarely have problems with the starter clutch, even though it is the same/similar design as the 650/700/750 starter clutches.

Good to know.
Steve