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Wayne S.
Wayne S., Motorcycle Mechanic
Category: Motorcycle
Satisfied Customers: 1255
Experience:  Experienced and Licensed Motorcycle Mechanic - all sizes and brands welcome.
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My boyfriend is trying to fix his daughter's ktm 105. The

Customer Question

Hi-my boyfriend is trying to fix his daughter's ktm 105. The kick starter is tight, with no give. Is there a trick with these? He is a very capable mechanic. Had it working, but as soon as he tightens the cover back on it tightens up again. Any ideas?
Submitted: 2 years ago.
Category: Motorcycle
Expert:  Wayne S. replied 2 years ago.


Hi, did you replace any parts and did you compare them to the
old parts for sizing? Did you torque the clutch hub nut?
Customer: replied 2 years ago.
Yes and yes. Replaced the shift location drum. Yes torqued clutch hub nut.
Expert:  Wayne S. replied 2 years ago.
Might be a spacer misplaced on the kickstarter.
If not, these are sensitive to the cover
gasket thickness and cover torque.
If you used the old gasket that might be the issue.
Make sure seal is not driven in too far
and kickshaft is clean and smooth.
This might help, very similar:
Customer: replied 2 years ago.
Hi Wayne,
You can link a picture or you would like us to link a picture?
Expert:  Wayne S. replied 2 years ago.
If you copy the links above and paste them in your browser
they will lead you to some helpful pics or movie.
Sometimes just a small clearance is required for
the kickstarter to clear. It might be the kick return
spring interfering or possibly another cover gasket
might do it if all else fails. Even two gaskets might work.
If you have any pics or new info that could also be helpful.
Let me know if you have any questions at all. I will be
back on a bit later today.
Customer: replied 2 years ago.
I didn't get the links...
Expert:  Wayne S. replied 2 years ago.
cut/paste these following addresses into your browser address bar
and hit return on keyboard.
This movie might help, very similar:

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