mrgem mrgem TT Silver Member; Members; 544 posts; Location: Colorado; Posted June 15, 2010. Fortunately, they weren't serious and it should function just fine. I got the job done for about $35 -- which includes the $16 spent on buying the puller set. 29:56 . by Eric N » Wed May 02, 2018 9:14 pm, Post Wanted - 1978 TS185 frame or frame&motor. That still allows your heel to shift, but moves your foot away from the kickstart lever. 250 four-stroke motocross bike comparison. Recommended Posts. I use a small two jaw puller when they are stuck. Any 60's or 70's triump/BSA/Norton has them. - Duration: 3:26. by otompotom » Wed May 02, 2018 2:08 pm, Post Next stop: Tool store for a small gear puller. I know it is very light alloy and subject to cracking. The good thing about telling the truth is that you don't have to remember what you said. Now fold open the lever as if you were going to kickstart the bike. We'll try to help. 10:00. Are ya having a problem with your rig? ". KTM MC 250 77 Husky CR 360 77, Husky 82 420 Auto Bitsa XR 200 project. The bolt acts as a puller and should significantly loosen the starter lever so you can pull it off by hand. I like to think "It shouldn't be this hard" when I'm working on stuff then I try to think like the guys who made the item I'm working on and try to imagine what they'd do and then suddenly I break something. You didn't say what bike it is and type of lever, I'm presuming it's one with a pinch bolt style. Regarding the warnings about damaging the case by using an incorrect tool: Once I got the kickstart off the shaft, I could see that my using a big open end wrench as a lever did put some nicks in the case right around the edge of the seal. The dealer wanted $140 to R&R the water pump (and replace it with new). The shaft should press out of the quadrant. You dont use the roll pins as the spline or drill them in from side you drill all the way thou the kick stater and the shaft one 5mm normaly works. When i want to shift up by heel, everytime i hit to kickstart lever. by Zyx » Fri Oct 16, 2015 8:24 pm, Post I will likely go shopping this evening for a small jawed gear puller. How to install the kick start gears on a 125-150cc GY6 four-stroke engine, common in scooters, ATVs, buggies, and karts. As a postscript to this thread: Once I conquered pulling the K/S lever, the rest of the job went very smoothly. When you shift with your heel, point your toes away from the bike. The sacrificial bolt is a good concept. by Lmo » Wed May 02, 2018 5:29 pm, Post The shaft should press out of the quadrant. The moral of the story? Yeah Holeshot was thinking what i was thinking. by RPG » Sun May 06, 2018 6:45 pm, Post You are going to find the puller pulls it so easy it is like you did not need it at all. Sears, Craftsman, for a reasonable part time use one.. Finally got the kick start problem sorted, Current bikes. All the best, RPG, Less fatiguing to use your toe to push down to upshift- no shin splints. Copyright© ThumperTalk, Inc. - All rights reserved.ThumperTalk® is a registered trademark. It is a pain In the butt to align the spring and lever with the spring under pressure, but it … Fix and or rebuild your striped kick starter KX, CR, KTM, RM. jo360 - justintendo replied above that the kick start spring and mechanism will unwind if I take the lever off without removing the case. Nathans Idea is a very good one as a temporary repair. The bike is completely stock and original and runs great. There is probably a groove in the shaft, much like the gear selector shaft...that will not allow you to pull off lever(kickstarter) unless the bolts have been fully removed first. Whether it falls off when you really need it or is just stuck on the shaft when you want to take it off, kickstarters can be a hassle. Eade Classic All parts in sydney or Union Jack or any brit bike places will have them. Login with username, password and session length, Husqvarnas: 78 390AMX, 82 430XC, 84 240WR, 84 500AE, 84 510TE, 87 510TE, you may be able to grind a flat on the shaft. It does require drilling in the end of the shaft between the shaft and lever (round key type) I find a couple of 3 or 4 mm pins usually does the job. You do not have the required permissions to view the files attached to this post. No big deal, I thought. See, wasn't that easy? Spray a little water on as you drill.This is also easier what of removing the kick starter as you can punch the roll pin out and replace it afterwards. Also, the kickstarter my come in handy someday . Location: England Husqvarna Motorcycle: More than I dare let her know Other Motorcycles: Yes! I am guessing the ratchet is press fit on the shaft and maybe the same for the lever on the outside. Not a pinch bolt style. I purchased new replacement from SH. Then get some steel rod of the same diameter as the drill hole, and put it in the hole. by otompotom » Wed May 02, 2018 10:48 am, Post lube the splines and prise apart where the clamp section of the K/Start grips .then attempt to remove the K/Start . How did it turn out? . First loosen the bolt holding the kickstarter, but don't remove it. Same one I recommend for the CS sprocket. Top. I have never seen JIS screws at the hardware or bike shop, and rarely see original, factory screws on any bike forty years old. And i got information from dealer that if i remove kickstart lever the shaft fall into gearbox. I've been running my 2014 for 15K kms without the kick start lever... the shaft has shown no signs of dropping into the tranny. 2020 Glen Helen 2 EnduroCross Race Report, 2020 Glen Helen 1 EnduroCross Race Report, 2020 Fox Raceway National Motocross 250 Class Race Report, 2020 Fox Raceway National Motocross 450 Class Race Report, 2020 Off-Road Bikes—Jordan Graham’s Ducati Scrambler Desert Sled. Can anyone explain correct installation procedure with regards to spring and pin orientation with the lever? I figured I could use them for other projects as well as this immediate need. Folding Kick start Assembly, Splined (forged) Foreign Made: Norton Commando 750/850: 40-3083 41-3020 57-2775: Folding Kickstart Lever Assembly To Suit 5/8″ Cotter-pin Shaft: BSA C15/B40: 54-3015: Chrome Kickstart Pedal Tapered Keyway Fitting: Triumph T10 Tina. 0 Members and 1 Guest are viewing this topic. Many products featured on this site were editorially chosen. I have found the Taiwanese bicycle crank cotter pins although they are identical in dimensions to the motorbike cotter pins, they are made from a softer material and i had problems with them otherday on a bike where the cotter pin kept wearing and comming loose. 2016 gear up asphalt grey, name Seryy Medved ,Air America CIA circa 1967/8 Vung Tau Viet Nam USS Tutuila ARG-4 (AND JUST A TOUCH OF AGENT ORANGE!). I tried to use the frame as my fulcrum point...although I did use some parts of the case where it has compound bends (strongest), but never subjected it to anything worse than steady pressure....Used PB Blaster (like a super WD-40), but no luck there, either. by viclioce » Sat Oct 17, 2015 7:25 pm, Users browsing this forum: No registered users and 8 guests, Powered by phpBB® Forum Software © phpBB Limited, The main Page for the Hodaka Club Discussion Group, I just bought my first Hodaka, Dirt Squirt model 01. 1971 R75/5 Gearshift lever and Kickstart removal I am in the process of replacing the Transmission in my 1971 R75 and am trying to remove the Shift lever and Kickstart lever,what is the proper way to remove the tapered bolt and to pull these two levers free from their shaft. However, most bikes have a built-in, simple and effective way to break loose a stubborn kickstarter-you just didn't know about it! "You are going to find the puller pulls it so easy it is like you did not need it at all. ; D Victor, Re: correct kick start lever installation. Mine was the same way, but some amount of lubrication, pulling, pushing, wiggling, and cussing finally worked. I appreciate all the warnings about putting pressure on the case. Copyright © 2020 Dirt Rider. PO removed kick starter for another bike. Then just put the rubber stopped back in. Oh and don't ask me how I know that . Try this. What size puller did you use? Removing Kickstart Lever. by captinr » Mon Oct 12, 2015 6:29 am, Post Dirt Rider may receive financial compensation for products purchased through this site. Both are so on there it's like they're welded. The original screws, so I hear, were JIS. Then, I realized the bike in the article was an electric-start only model and I had a kicker. After a few weeks of riding, I found everything settled in and I got use to the unique layout of the machine. fotosaurus, May 22, 2014 #9. stormer254 Husqvarna AA Class . Frame # TS1852-24007 up to TS1852-39022. 2005 Gear-Up, Mr. Nat_ural 108,000+ Kilometers and counting. good luck. Remove the cotter pin with the pressure applied to the threaded end. if that's true i wouldn't remove the lever for sure. by brianural » Wed May 02, 2018 9:25 pm, Post Reproduction in whole or in part without permission is prohibited. Also drill the hole slightly smaller than the pin with the lever clamped up tight, loosen the lever bolt and drive the pins in and retighten the clamp bolt. where would i find a small 2 jaw small puller though? By - Shorter lever makes starting in tight spots easier . I'll just remove the bolt holding the k/s lever on its splined shaft and pull the K/S lever. As others have mentioned, it takes some time to get use to the Ural layout.

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