BiggDogg
01-25-2012, 09:41 PM
Hi Gang, There are a ton of usefull videos found on replacing the cords for Hondas but I haven't noticed any for the Kawasaki KLT's, and the Kawasakis are a little different so I thought since I had to fix mine, I would take pictures.
Mind you I am not technical therefor I probably wont be calling these parts by their technical names.
Have about 8ft or more of cord with you
Started off with a ripped cord so I removed the whole pull start off the trike and decided to sand off the rust and paint it
tapped up the Kawasaki logo
140470
140471
140472
unlike hondas that have a nut back there, this has a C-Retaining clip keeping it all together
140473
put some pressure on the back to releive pressure off the clip and slide the clip off. I used the tip of a screwdriver to help me
140474
you don't have to worry about some crazy spring force once you remove the clip
next carefully remove the back and you will see a spring in the center surrounded by 3 bent thin wires. keep the wires in place but its ok if they come out. just put them back if they do
140475
pull the entire piece up out of the case,you can remove the little center spring and washer first or pull it out with the whole thing. it doesn't matter just don't lose them. behind the peice is the coil spring but its set in their and isn't going anywhere.
pull the knot and rest of the ripped cord out the back
140476
slide your new cord in and tie a knot and pull it tight so that the knot is out of the way from the spring
140477
140478
now slide this whole peice back onto the D shaft, make sure the washer under the sprin lines up (it to is D shaped) so its pretty fool proof
that coil spring has a loop on the end which catches a hook on the back of the apparatus the cord is rolled up in. There is no need to worry about lining them up because they only catch each other when turning the counterclockwise way. now once you put that c-clip on, you can start to wind it. since you are winding it the opposite way that it goes when you pull, there is no spring tension on it so u don't need clamps like you do with the Hondas.
Just wind and every now and then pull the cord and see what kind of tension you have on it. you will see it give force and retract the cord back out off you hand.
once its done retracting the cord from you then you will be able to cut the cord and knot it up around your handle. it's up to you how much cord u want to pull out before it runs out. My coil took about 4-5 ft of cord
140482
now just reattach after making sure there is no slack after you pull the cord and it retracts back
140481
140483
I really hope this write up made sense. It really isn't hard at all.
Mind you I am not technical therefor I probably wont be calling these parts by their technical names.
Have about 8ft or more of cord with you
Started off with a ripped cord so I removed the whole pull start off the trike and decided to sand off the rust and paint it
tapped up the Kawasaki logo
140470
140471
140472
unlike hondas that have a nut back there, this has a C-Retaining clip keeping it all together
140473
put some pressure on the back to releive pressure off the clip and slide the clip off. I used the tip of a screwdriver to help me
140474
you don't have to worry about some crazy spring force once you remove the clip
next carefully remove the back and you will see a spring in the center surrounded by 3 bent thin wires. keep the wires in place but its ok if they come out. just put them back if they do
140475
pull the entire piece up out of the case,you can remove the little center spring and washer first or pull it out with the whole thing. it doesn't matter just don't lose them. behind the peice is the coil spring but its set in their and isn't going anywhere.
pull the knot and rest of the ripped cord out the back
140476
slide your new cord in and tie a knot and pull it tight so that the knot is out of the way from the spring
140477
140478
now slide this whole peice back onto the D shaft, make sure the washer under the sprin lines up (it to is D shaped) so its pretty fool proof
that coil spring has a loop on the end which catches a hook on the back of the apparatus the cord is rolled up in. There is no need to worry about lining them up because they only catch each other when turning the counterclockwise way. now once you put that c-clip on, you can start to wind it. since you are winding it the opposite way that it goes when you pull, there is no spring tension on it so u don't need clamps like you do with the Hondas.
Just wind and every now and then pull the cord and see what kind of tension you have on it. you will see it give force and retract the cord back out off you hand.
once its done retracting the cord from you then you will be able to cut the cord and knot it up around your handle. it's up to you how much cord u want to pull out before it runs out. My coil took about 4-5 ft of cord
140482
now just reattach after making sure there is no slack after you pull the cord and it retracts back
140481
140483
I really hope this write up made sense. It really isn't hard at all.