Kickstand Install
From Unofficial Zero Manual
This installs or replaces the Kickstand.
See also/first Kickstand Removal.
- Tools
- Center lift or stand.
- Large flat-blade screwdriver or specialized tool like drum brake spring pliers for spring removal and replacement.
- E-clip tool (or needlenose pliers) for the 3/8" E-clip.
- Steps
- (When replacing) Remove the allen bolt securing the springs to the old kickstand.
- (When replacing) Transfer the 2 bronze bushings from the old kickstand:
- Remove the 2 bronze bushings from the old kickstand.
- Clean and grease bushings.
- Insert bushings into new kickstand and replace chamfered bolt with springs.
- My chamfered bolt was not very tight and I assume it was being held in from the spring tension.
- I went to tighten it all the way in but that seemed to push the springs out too far.
- I put blue Loctite on it and threaded it about half way in.
- I will check this after a few rides to ensure it does not fall out!
- Place the new kickstand onto the pivot.
- Install the pin and spring
- Pin Before Spring
- Insert the pin.
- Raise the kickstand to its stowed/horizontal position.
- This minimizes the amount of force/extension to install the new spring.
- Install the spring over the kickstand hook with a suitable tool (see tools requirements).
- Spring before pin
- Have the pin and a tapered punch that fits nicely in the hole ready to go.
- Clean the pin and apply fresh grease to it.
- Hook the springs onto the frame, grip the kickstand with both hands, put your shoulder into the bike so it won’t tip.
- While pushing straight down on the kickstand, get it onto the frame and insert the tapered punch.
- Now raise the kickstand into the stowed/horizontal position.
- Remove punch.
- The hole will be almost aligned.
- Insert the pin as far as it will go, mine stopped at the frame.
- With the kickstand still in the up position, tap the bottom of the kickstand pivot area up towards the frame with a dead blow hammer while pushing the pin in.
- This should align the hole and allow the pin to go right in.
- Insert the pin and fasten it with a new 3/8" E-clip.
- Note: This is the most difficult and dangerous part of the job.
- Use eye protection while doing this and ensure your hands won't be damaged if the spring flies back while getting it over the hook.
- Focus on applying steady force with as much leverage as possible to extend the spring back along the swingarm.
- One trick is to use a strong line looped through the hook as a pulley.
- Another trick is to bend the spring enough back and forth to insert pennies between the coils, which holds it in an extended position.
- Then loop the spring over the hook and pull the pennies out with pliers.
- Check the operation of the kickstand a few times.
- Ensure that it operates smoothly.
- Ensure the kickstand sensor detects the position of the kickstand, by checking the interlock indication on the dash while the bike is keyed on.
- Put the kickstand down before letting the motorcycle off the lift to rest on it.
- References
- Kickstand replacement basic how to in Say10 easy steps by Say10 for FX.