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ADVrider > Mr-Cob  > Motorcycles > How to install a kick starter on the DRZ400S
This is one of the best modifications that I have done to the DRZ400S. Stock, this bike does not have a kick starter, this is something I was never comfortable with. The Kick Starter Kit, that is sold by Suzuki lists the kit as only fitting the DRZ400E, the kit WILL FIT the DRZ400S, the DRZ400S cylinder head is not machined to accept the manual decompression lever, so it and it's associated parts are not used, the rest of the kit bolts right in. A couple of weeks ago while deep into some very nasty mountain terrain, the battery failed and I had a Hell of a time getting back to where the truck was parked. That was it, never again, I decided to install the kicker. In this gallery you will find detailed step by step photos and commentary describing how to accomplish this task. Life is good. This gallery has had photos added that MAKE CLEAR the installation of the kick starter stopper. Thank you "Mark Kanzler" for supplying these photos
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Here is what I started with, a stock bike that does not have a kick starter to back up the electric start.
Here I have removed the skid plate, the rear brake pedal, drained the oil and the coolant from the radiator.
Now I am getting to the part where I must pay close attention. Here the clutch cover-side case has been removed.
Here the six bolts that hold the clutch pack have been removed allowing the removal of the entire clutch pack as a unit. the clutch throwout bearing rod can also be removed at this time.
After the clutch pack is removed, I straightened the lock washer that secures the large nut holding the clutch hub sleeve. The tip of the small screw-driver is pointing at the bent over edge of the washer that must be straightened. After the washer is straightened, remove the nut. I used an impact wrench, if you don't have an impact wrench, you must block the clutch hub sleeve from rotating, this can be done with a special factory tool, a bent a piece of metal or a small wedge made of wood.
Here the clutch hub sleeve and the and the primary driven gear assembly have been removed.
Now I removed the spacer retainer. I used a hand impact driver and a hammer to loosen the two screws holding the retainer. After you remove the retainer, remove the spacer that is on the drive shaft. Once this is done, the tear-down phase of the operation is complete, and the kicker installation begins.
Here you can see the what the bike looks like when all of the disassembly has been done. The bike is now ready to have the kicker kit installed. Sit back, pop a cold one and READ the instructions that come with the kit, some of the writing and drawings that accompany the kit are not the best.
The first step to installing the kicker is to bolt the "kick starter stopper" in place, there is another part that is installed in this step, it is hidden BEHIND the part that is shown with the outward-rear facing tang. I used blue Loc-Tite, to secure the small gold colored Allen bolt that holds these two parts in place. Make SURE the top part is mounted with the "STOPPER" pointed out-wards.
Here is what I started with, a stock bike that does not have a kick starter to back up the electric start.
Here is what I started with, a stock bike that does not have a kick starter to back up the electric start.
Here is what I started with, a stock bike that does not have a kick starter to back up the electric start.
Sony CYBERSHOT |
More details: exif |
Original size: 1280x960 |
Current: 800x600 |
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