Topic: cb400f kick start pivot cracked

[awrawr]

I have two of these and they are both cracked. I assume this is a common fault but I cannot find any replacement parts for sale anywhere and a lasting repair seems unlikely, given the small size of the piece of metal that is broken, right at the point of maximum stress.

Has anybody solve this problem? Or know a source of replacements?

[robvangulik]

It is common alright, i welded it and grinded it in the right shape some 10 years ago and been OK since, i must say i hardly ever use it, it mostly starts electric first push on the button.

[MoMo]

I've had 8 400 fours and none had a kick start problem.  Is the lever cracked?....Larry

[awrawr]

See pic. I blame the crack on abuse arising from frequent dirty winter weather, salty roads, damp electrics and consequent difficulty starting. If all else fails I will try the weld since I do not anticipate using the bike in poor weather and should be able to rely on the starter button with electronic ignition, better maintained electrics and dry-running only.

I was surprised after-market replacements are so hard to find.does anyone know of an alternative model with a matching part? There's several look-alikes but difficult to judge diameters and angles from pictures.

[robvangulik]

Here is my welded kicker..

[jakec]

My roommate's 400F has a totally incorrect kickstart lever, a small one like for a small twin. I always wondered why this would be the case but maybe his was broken in the past.

[awrawr]

Maybe it's just God's way of telling me to lose weight and keep my timing and carbs properly adjusted............

[Bodi]

I believe this is just a weak point. Mine cracked, I rooted through several huge bins of kickstart levers (hundreds of them) at two local bike wreckers and did not find any 400F ones or any others that would work. I had it welded two or three years ago, and this year it's cracking open again. I will try and have it welded again but rely on electric start for cold starts now - this is when a lot of kicks would be required, I always kicked it over for this to save battery charge.

[carnivorous chicken]

Pretty sure I've got a kicker if you need one...

[calj737]

I will try and have it welded again...

The trick to welding this part is an adequate preheat, and a slow cooling. If whomever is welding it just fires up, lays a bead, and then tosses the part aside, it will crack after stressing it. It's cast steel and needs proper treatment to remain strong.