Remove/replace kickstart shaft bushing? (2011)

Anyone know how to go about doing this? The kickstarter I'm going to use in my bike (replacing the oddball POS I bought from England) has a bit of wiggle to it so I was going to install a new bushing to make sure it was tight once installed.

I can't figure out how to get the old bushing out. Also, any tips on getting the new one in (aside from just "have it pressed in!") would be appreciated.

Thanks,
-Jordan

Toss it in the oven at 250 for about 15 minutes, then smack it down against a wooden board (patio deck?).

It should start to work it's way out, or maybe even fall right out entirely.

Yup, like alot of fitting on Norton's it's all about interference fit using cold to shrink the part being inserted into the heated part that opens up to accept it. Do it fast ,not unlike quick sex.

I assume you are talking about the steel bush in the outer gearbox cover and not the brass bush in the kickstart shaft? It is unusual for the steel bush to wear. Being much stronger than the aluminum in the cover, it is more likely the cover will wear first. However, if it is not loose in the cover I don't see how this could be the problem.

If it is the kickstart shaft wobbling on the layshaft, you need to replace the brass bush in the kickstart shaft. This one will not fall out with heat. This bush is in a blind hole in the end of the shaft and the best way to remove it is with a large tap. Cut threads in the bush and use a proper size bolt to extract the bush by using washers under the bolt head. Or as a friend of mine did, sacrafice a pipe tap by welding it to a section of threaded rod and use a small section of pipe and nuts and make a slide hammer.

The brass bush in the kickstart shaft will hydraulic out - done it many times. fill shaft with grease and blank off return spring hole in a vice with soft jaws or bits of wood and tap in the layshaft and the bush flies out. The steel bush you remove the o ring and tap it out with a screwdriver its not a very tight fit.

myjota said:

The brass bush in the kickstart shaft will hydraulic out - done it many times. fill shaft with grease and blank off return spring hole in a vice with soft jaws or bits of wood and tap in the layshaft and the bush flies out. The steel bush you remove the o ring and tap it out with a screwdriver its not a very tight fit.

Click to expand...

This grease/hydraulic sounds like a great technique for the blind bush removal in the kick start shaft.........anyone done this lately?

p400 said:

myjota said:

The brass bush in the kickstart shaft will hydraulic out - done it many times. fill shaft with grease and blank off return spring hole in a vice with soft jaws or bits of wood and tap in the layshaft and the bush flies out. The steel bush you remove the o ring and tap it out with a screwdriver its not a very tight fit.

Click to expand...

This grease/hydraulic sounds like a great technique for the blind bush removal in the kick start shaft.........anyone done this lately?

Click to expand...

When I last tried it, it didn't work; I'd just stick it in a lathe and turn it out.

p400 said:

myjota said:

The brass bush in the kickstart shaft will hydraulic out - done it many times. fill shaft with grease and blank off return spring hole in a vice with soft jaws or bits of wood and tap in the layshaft and the bush flies out. The steel bush you remove the o ring and tap it out with a screwdriver its not a very tight fit.

Click to expand...

This grease/hydraulic sounds like a great technique for the blind bush removal in the kick start shaft.........anyone done this lately?

Click to expand...

Don't forget the rag wrapped around... :idea: :shock:

In his dvd on gearbox rebuild Mick Hemmings recommend driving a large tap into the bush then holding the shank of the tap in a vice. Then with hide hammer drive the shaft off the bush (warm the shaft carefully if it doesn't want to come off). This method worked for me and I have seen it used to remove triumph cam bushes. Just make sure the tap is not bigger than the O/D of the bush so it doesn't bit into the other part.

grandpaul said:

Toss it in the oven at 250 for about 15 minutes, then smack it down against a wooden board (patio deck?).

It should start to work it's way out, or maybe even fall right out entirely.

Click to expand...

I know this is an old thread but I followed grandpaul's excellent advice and both kickstart steel and then exchange bronze bushes popped out a treat after a few slap downs on a large flat piece of wood (my wife's chopping board but don't let on!) Thanks again!