How Do I Wind a Husqvarna Kick Starter?

Use a good pair of locking pliers to wind a Husqvarna kick starter.

Husqvarna motorcycles are designed with kick starters that automatically return to the upright position each time you kick over the motorcycle. This feature prevents the kick-start lever from dragging when you lean the bike to the left. The lever attaches to the outer end of the kick-start shaft. A coil spring inside the engine case winds tighter when you push down on the lever. In many cases, if the lever doesn’t return to the fully upright position, winding the spring restores the necessary preload. The job requires basic mechanical skills and hand tools.

Things You'll Need

• Oil pan
• Metric hex wrench
• Metric socket and ratchet
• Large locking pliers

Instructions

1. Place an oil pan under the left side of the engine below the kick-start lever.

2. Loosen the fixing bolt at the base of the lever with a metric hex wrench. Grip the stem of the lever with one hand. Move the stem inward and outward as you pull the base of the lever off the end of the kick-start shaft.

3. Loosen and remove the bolts at the case cover with a metric socket and ratchet. Save the bolts. Pull the case cover off by hand. If the shaft seal did not come off with the cover, pull the seal off the shaft and press it into the recess on the inside of the cover by hand.

4. Pull the metallic sleeve off the shaft by hand. You'll notice the sleeve has groves in the inner surface that mesh with splines near the end of the shaft, and a slot for the hooked end of the return spring.

5. Push the sleeve onto the shaft just enough to fit the hooked end of the return spring into the slot without the grooves engaging the splines on the shaft. If necessary, rotate the sleeve so the hooked end of the spring fits into the slot.

6. Grip the sleeve firmly with large locking pliers. Rotate the sleeve one full turn clockwise to wind the spring. Push the sleeve fully onto the shaft so the grooves mesh in the splines. Release the pliers.

7. Fit the engine case in place, making sure the seal seats around the kick-start shaft. Secure the case with the saved bolts and the socket and ratchet.

8. Hold the kick-start lever vertically as you push the base of the lever onto the end of the shaft. Tighten the fixing bolt at the base of the lever securely with the metric hex wrench.

Tips & Warnings

• Consider installing a new spring for long-term reliability.

References

• Motorcycle Specifications: 1999 Husqvarna TE 410
• Hot Manuals: Husqvarna TE 350 TE 410 TE 610 TC 610 1990 -1999 Service Repair Manual