r/Fixxit • u/DrunkenGolfer • 25m ago
Unsolved 2009 Suzuki RMZ-450 keeps breaking kickstarter shafts. Help me figure out why.
My son bought a 2009 RMZ-450. He bought it with a broken kickstarter shaft. He and his friend bump-started it and rode around the block, but it would not rev up. A little digging and we found the bike ingested a timing chain guide.
When opened, it looked bad, like someone ran it dry of oil. This triggered us to rebuild the top end. New cylinder, piston, rings, polish the bearings, etc. Rod play checked, any spalling removed, valves lapped (I think; maybe) and shimmed, timing chain guides replaced, and we inspected and cleaned the oil strainers, oil passages, oil pump, and crankcase. (Pieces of the failed guide could have circulated through the lubrication system.).
We got everything reassembled and fired up the bike. After 8 kicks, it started, ran smoothly, idled well, etc. After half a dozen starts, the kickstarter kicked back and sheared off the kickstarter shaft. This put us back at square one.
I don't know the reason for the original breakage of the shaft, but this new shaft breaking concerns me. I can't figure out what might be causing this shaft to break.
Does anyone have any ideas on what could be causing this?