Mine gets wedged by the foot peg too. The issue is the stop notch on the kick starter dose not line up with the stop block on the ped, so it gets chiseled out and makes a wedge shape. Some guys have built up the weld on the starter others have built up the block on the foot peg. I tried putting heat shrik on the kick starter shaft but it tore through. I try not to kick it to hard, but kicking it to hard is a better option than getting the knee in the jaw jolt from a kick back!
Originally posted by Jon K. That's weird; must be something jamming when it is in the down position. Of course you have looked for marks on the kickstarter where it might be jamming on the frame, footpeg, etc.
Perhaps the shaft itself is bent somehow. Where it comes through the cover.
Sounds like the cover is going to have to come off.
Its normal, like I said, the stop tab on the kicker dose not line up right with the block on the footpeg. No bent shaft, ect in most cases. As you hit it, it weares the kicker and the corner of the stop tab into slants, a good hard kick will cause it to wedge in there. Some people build up the parts to line up better, me, I just filed down the block on the foot peg so it would not wedge. It is wearing through my kick starter though :( .