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kick start lever removal

 
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kick start lever removal
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davidgwells



Joined: 08 Feb 2009
Posts: 111
Location: chicago

Post kick start lever removal Reply with quote
After searching for quite awhile I haven't found what I'm after. For those who have removed your kick start lever, how did you do it? I've got the bolt loose and the lever won't budge. I'm assuming it's on a tapered press fit shaft and I need some sort of puller tool?
Wed Apr 15, 2009 7:19 pm View user's profile Send private message
rufusswan



Joined: 29 Sep 2007
Posts: 1786
Location: Taneyville, Missouri

Post Reply with quote
I doubt that it's tapered. With the bolt removed use a big screwdriver in the split that the bolts compress to wedge it apart. Then 'persuade' it to slip off.

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Wed Apr 15, 2009 7:51 pm View user's profile Send private message Send e-mail MSN Messenger
davidgwells



Joined: 08 Feb 2009
Posts: 111
Location: chicago

Post Reply with quote
The bolt is out and my screwdriver was bending(it's a pos). I'm going to rig up a puller of some sort.
Wed Apr 15, 2009 8:22 pm View user's profile Send private message
Crusader Tom



Joined: 10 Aug 2008
Posts: 513
Location: Kansas City, Kansas

Post Reply with quote
soak that bitch with WD-40 or Liquid-Wrench... the get very rusted and stick like a big dog. the bolt has to be completely out(the shaft has a notch for it)... but it's not coming off because it's rusted. thats why Vespa uses aluminum kickstarts...

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Thu Apr 16, 2009 11:27 am View user's profile Send private message
matty_x



Joined: 06 Apr 2007
Posts: 1065

Post Reply with quote
I did a how to on this...

http://retrobajaj.informe.com/refitting-kickstart-mechanism-oil-seal-dt845.html

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Last edited by matty_x on Thu Apr 16, 2009 6:31 pm; edited 1 time in total
Thu Apr 16, 2009 2:00 pm View user's profile Send private message
dirkhunt
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Post Reply with quote
Matty, that link ain't right.....
Thu Apr 16, 2009 4:00 pm
matty_x



Joined: 06 Apr 2007
Posts: 1065

Post Reply with quote
edited my post and fixed the link.

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Thu Apr 16, 2009 6:31 pm View user's profile Send private message
davidgwells



Joined: 08 Feb 2009
Posts: 111
Location: chicago

Post Reply with quote
Thanks Matty, I will try the pry bar. My scoot isn't leaking oil but now that I saw your pics I see that the rubber bushing is out a bit on mine too. I was going to paint the kick lever but now I'm going to hold out for the polished aluminum one.
Thu Apr 16, 2009 8:35 pm View user's profile Send private message
matty_x



Joined: 06 Apr 2007
Posts: 1065

Post Reply with quote
DO NOT FORGET THE LAST STEP!!!!! It's without a doubt the most important.

Cool

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Thu Apr 16, 2009 11:09 pm View user's profile Send private message
Ronin



Joined: 25 Mar 2008
Posts: 119
Location: Royal Oak, Michigan, USA

Post Reply with quote
Awesome write-up. I might just go do that for the hell of it.

I sometimes like to start a list backwards.

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Fri Apr 17, 2009 3:54 pm View user's profile Send private message
davidgwells



Joined: 08 Feb 2009
Posts: 111
Location: chicago

Post Reply with quote
Crap. I must not be able to follow instuctions. I did the last step first, repeatedly!
Fri Apr 17, 2009 4:00 pm View user's profile Send private message
dirkhunt
Guest





Post Reply with quote
I wonder if Al still has any of these left....

http://www.bajajusa.com/Accessories.htm

$35 for a forged Aluminum kick lever.....
Mon Apr 20, 2009 5:29 pm
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