huh, a few bites
i dont have picsz as its very straight forward.
what i did step by step...
1: remove the clutch cover.
2: i already had my clutch removed, i dont think with it being there already will make any difference.
3:remove the sump and filter mesh (just pulls out)
4: take a pic of the existing setup incase you forget the orientation when reassembling AND have a look behind the main spring on the clutch side how it locks onto the case and how the shaft has a stopper that presses against the case too.
5: remove the circlip on the clutch side, be careful the spring behind it has a fair amount of rotational tension, but it doesnt shoot off or anything.
6: i didnt have a 90 degree outside circlip pliers which would have made my job a million times easier. Due to that, i used two flat screw drivers to remove the inside circlip at the end of the shaft on the inside. get the one side out of the recess, hold it in place and then remove the other out f the recess. Then you can slowly slide it off the end. BE SURE TO KEEP YOUR FINGERS ON IT AS IT WILL SHOOT OFF AND DISAPPEAR. Dont just pry it off, it will bend and be useless. Its all good if you have a spare though. mine was a little out of shape, but by like a 1mm or two.
7: remove the little washer right behind the circlip.
8.now, the next step is a two fold process. there is a black bracket that locks into gear that engages (and disengages when not in use) the main kick start gear that drives the starter gears in the gbox (if thats what they are called
) it comes off together preferably. you will notice that the bracket also locates in the casing of the motor as well. It also depends on the rotary position of the shaft, the bracket has a tab that may be locked in the gear that engages the main Kick start gear, so its better to come off together as mentioned above or you can twist the shaft some and remove the bracket and engaging gear independently, You will see what im going on about when you are at this step.
9: there is a spring between the bracket and engaging/disengaging gear with a washer and another washer that has a square centre (placed up against the engaging/disengaging) gear that allows only one way to fit it to the square shaft. they are together so be careful to make sure you have them both after removing.
10: after removing the above bracket, spring and engaging/disengaging gear (washers included) there is another large spring that keep the engaging/disengaging gear away from the main kick start gear as it spins with the rotation of the motor. Thats how the kick start works. You push on the kick start pedal, the engaging/disengaging gear is pulled in and engages the main kick start gear turning the motor over.
11: Then you need to pull the main kick start gear off the shaft. It could slide off wilt a little pulling from the outside of the shaft, or you may have to get some little wedges of wood or the like to hammer lightly in between the case and the gear to slide it off the shaft. i used a vice grip on the outside end of the stuffed shaft, and tapped it with a hammer to pull the shaft out and leave the hear on the inside....once its off...
12: remove the shaft.
you will be smiling now..... if not, smile
Now, some more tips...i place my motor (oh, by the way my motor is out of the frame) with the back end of gearbox on the floor so the sump is facing you. That way, if anything falls, it wont drop into the gears. If its in the frame, you just need to make sure there is enough space under the bike to lie down and have enough space to swing your arms around a bit...
the reassembly parts is the exact opposite of dissembly. Accept, you will be fitting a new shaft
and...
The main spring on the clutch side first, what i did is locate the piece that fits on the case first, then put the actual kick start lever on the nice new shafts spline (
) and use it as leverage. i cant remember which way you twist, but you will need to get the other end of the spring, short loop hooked into the shaft and while under a bit of rotational tension, slide the locking block on the shaft in to the motor. you will see what i mean. you observed it before you removed it...remember point #4
tips, make sure the engaging/disengaging gear and its big spring between it and the Main kick start shaft is lightly compressed (its very weak dont stress) while fitting the washers as the one is square centred (remember) and needs to slide on the square shaft before the smaller spring and bracket is fitted. otherwise you will battle to fit the last washer and circlip on later. You will see what i mean, youll be an expert by this time. hahahha
you would have noticed that you will need to rotate the shaft a bit to get the bracket and engaging/disengaging gear to line up wit the engaging/disengaging gears locking thing on the side.
other than that, its a slightly fiddly job, but its not rocket science
As you can see its pretty comprehensive
i dont think i have forgotten anything. and hour of typing later
questions?
hahahaha
