i was wondering if anyone has a solution to getting rid of the kicker slop. i have just rebuilt my kicker with all new
parts ( washers and such ) one problem i encountered is that i could not fit the last washer that goes on the outside of the kick starter gear right before the clip goes on. i had no room for it? has anyone made any bronze bushings for the kickstart gear? i have already broken a side case on my donor bike and want to take every precaution to not have that happen again. thanks for any info
-cheers
kicker cover and kicker slop?http://www.westernhillshondayamaha.com/ they have what you need.
Re: kicker cover and kicker slop?I made one. I found a brass bushing at Farm and Fleet that was close. I did a lot of hand sanding to reduce the outside diameter so if fit snug into the case. I cut it to size then drilled a hole to line up with the grease fitting before inserting the bushing. I also fabricated an aluminum sleeve over the kick shaft to take out a little play. I don't know how this will wear under frequent use but I have never intended to use it except for if the battery went dead. Now that I found my charging problem, I have not had any issues with a low battery. Gunner gunner that is awesome. so you made the sleeve due to taking a bit too much material off on the bushing? i think im gonna make some bronze bushings asap since my bike is kickstart only. were you able to fit both thrust washers on the kicker shaft? also is the bushing one solid piece? i have a couple of kicker covers where the bushing looks like 2 pieces. sorry for all the questions but i need to get the kicker nice and snug.
-cheers
The outside diameter of the bushing was slightly larger than the hole in the case, the inside diameter was slightly larger than the shaft. I made it one piece. I just found the part I cut off, it's 1" OD, 3/4" ID. I sanded down the outside so it fit in the case, I put the sleeve on to make the shaft fit tighter in the bushing.
I am not sure what the stock bushing looked like. Mine was black and looked like a plastic material. It had a piece broke out, and it also broke a small piece of the case. I filled this with JB Weld. I wish I took some pictures, but I really didn't know for sure if it was going to work until I had it all together. All the washers that came off, I put back on. I think there was one on the outside under the clip, and there was on on the inside. I greased the shaft well when I put it back together, then pumped more in through the grease fitting. I have a tooth missing on the gear so I never planned to make this fully functional at this time. My goal was more to fix it so it didn't rattle around. I have used it and it works. I'm not sure I would want to use it all the time. It would be nice to have a tighter fit between the shaft and bushing without having to use a sleeve. Gunner
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