This post was very helpful when I did the roller layshaft bearing replacement today.
One note: the rear isolastic shims required on the layshaft to achieve the desired end play must have their internal diameter properly sized
to fit the kickstart shaft. The KS shaft has a machined radius that is slightly larger than the diameter that passes through the inner cover.
Although they slide over the shaft, they may not butt up against the pawl face unless they can fit over the radius.
Note the gap in the photo.
I needed 0.030" of shims to get a good fit.
The original ball bearing was a 6203 made in Great Britain and in good shape.
One note: the rear isolastic shims required on the layshaft to achieve the desired end play must have their internal diameter properly sized
to fit the kickstart shaft. The KS shaft has a machined radius that is slightly larger than the diameter that passes through the inner cover.
Although they slide over the shaft, they may not butt up against the pawl face unless they can fit over the radius.
Note the gap in the photo.
I needed 0.030" of shims to get a good fit.
The original ball bearing was a 6203 made in Great Britain and in good shape.
