About to start the kick starter kit on my 450 XCF...

thejean · Nov 10, 2014

And I have a few questions...

Instructions say I need special tools (engine blocking screw, marking mandrel for balancer shaft and clutch holder). But are the an absolute must have or can I just improvise (as I usually do)?

I'm guessing the engine blocking screw is just a longer screw to prevent the engine from turning.

Can't imagine I need a clutch holder (certainly didn't on my 300).

No idea what the mandrel is...?

I've built car engines before and always when they say I need a special tool I've always found a way around it but I have no idea when it comes to these bikes.

Thanks, JC

RMK800_Karma · Nov 10, 2014

No advice as I just had mine installed by the dealer, Carl's in Boise, for less than $150.00. For the price it wasn't worth doing it myself. The kit works fine.

WaBackcountry · Nov 10, 2014

Is this available for 2013 450sxf? Part number? Dealer told me its not available but others have said it is? I see spot in case where it should go.

chumbilly1 · Nov 10, 2014

Dangle, You need to talk to one of the larger , more reputable ktm shops. They are not in WA unfortunately. Munns in TX ,Cyclezone in KS, KTMpartshouse.com or if Carls has it they are closer. You basically order it by part #. Another good place to research this is KTMtalk.com.

Revv Up · Nov 10, 2014

I'd be willing to bet you can do it by improvising, first off why would you need to lock it on TDC just to install a kickstart or lock the clutch in any position?

thejean · Nov 11, 2014

WaBackcountry said:
Is this available for 2013 450sxf? Part number? Dealer told me its not available but others have said it is? I see spot in case where it should go.

Yes it is. Order the kit for a 2013 Berg 501. All of the parts come in ktm boxes.

thejean · Nov 11, 2014

anonny said:
I'd be willing to bet you can do it by improvising, first off why would you need to lock it on TDC just to install a kickstart or lock the clutch in any position?

No idea. It just says to do it. Doesn't make sense to me either.

the gman · Nov 11, 2014

Had a riding buddy have this done to his 13 by a dealer and he told me that the dealer had to do something to the map in it to alow it to start??? Anyone else here this as my son is talking about putting one on his 13. I am hoping he just misunderstood the dealer.

thejean · Nov 11, 2014

Well, given its EFI I can see needing a reprogram. It's possible it was just that particular bike though.

thejean · Nov 11, 2014

Done. Feel much better now. Once I get the bike completely back together I'll let you know if a reprogram is required or not. The FI light came on when I kicked it over so I think I will be ok.

bdoe22 · Nov 12, 2014

timing

the water pump is actually timed. so if you remove it before timing the wp to the crank shaft you will have a hell of a time getting it put back together in time....yes the mandral is not mandatory.but you will need to come up with a way to time it.

bdoe22 · Nov 12, 2014

waterpump

thejean said:
No idea. It just says to do it. Doesn't make sense to me either.

because the waterpump needs to be removed see above post

thejean · Nov 12, 2014

The instructions seem to make it fairly easy. According to it you simply put the dot on the gear wheel in line with the screw that goes through where the supposed special tool goes. I just stuck a bolt in and lined it before reassembling the cover. It did appear to to be 3 or 4 teeth off though when I took it apart. But I reassembled according to the instructions.

Curious what that weight on the water pump gear is for anyway - to balance the motor?

sidehillsam · Nov 13, 2014

Timing water pump?

Thanks for the heads up. I did not know adding kickstarter involved timing the water pump! Dealer installed the kicker in 1 hour. Hope he reassembled correctly, very likely I wouldn't have. I'll pester him tomorrow.

mrquick68 · Nov 13, 2014

i did this same kit on my 14 Berg 501. Not difficult at all, and didn't need any special tools, just a brain. the reason it needs to stay at TDC is because the water pump is "clocked" as its driven off the balance shaft that sits in the clutch cover case. as long as you line up the "dot" on the balancer with the hole in the cover and keep it at TDC you'll be golden. It's kinda scary once opened up (lots of gears and such), but just follow the directions and all will be well. You can see if its at TDC two different ways (remove the valve cover is the most fool proof, or look through the hole (arrow) and see the HASH mark on the crank. you can actually run the bolt through the hole and it will be lock the crank in place if you are worried about it moving.

mrquick68 · Nov 13, 2014

WaBackcountry said:
Is this available for 2013 450sxf? Part number? Dealer told me its not available but others have said it is? I see spot in case where it should go.

check your case to make sure there is a place for the kickstarter, if there is, then the kit exists. It's the same kit for all the bikes i believe. It should be about $240.

bdoe22 · Nov 13, 2014

450/500

HUSKY/KTM # 78112946044

RMK800_Karma · Nov 13, 2014

If anyone still has any questions on the correct part number, call Jake at Carl's in Boise at 853-5550. He will know exactly what you are asking about as he had to bird dog mine from KTM directly to get it. He won't forget the experience if you mention mine. Mine was on backorder for over two months but finally arrived and I had Carl's go ahead and install it and it works fine.

fskid · Nov 13, 2014

Just ordered mine straight from ktm hard parts catalog $215 free shipping

thejean · Nov 15, 2014

RMK800_Karma said:
If anyone still has any questions on the correct part number, call Jake at Carl's in Boise at 853-5550. He will know exactly what you are asking about as he had to bird dog mine from KTM directly to get it. He won't forget the experience if you mention mine. Mine was on backorder for over two months but finally arrived and I had Carl's go ahead and install it and it works fine.

And I presume no reprogram was required?

About to start the kick starter kit on my 450 XCF...

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