kjhansen52
New Member
I have a 1982 CT70. Anybody have a step-by-step procedure for changing the kick starter shaft?
Keith
Keith
Procedure for replacing the kick starter shaft
- Thread starter kjhansen52
- Start date
Lots of things to do. Remove cylinder head. Remove bolts on both engine cases. Remove clutch and shift linkage. There should be a bolt covered by a black plastic cover on the flywheel side of engine. That also has to be removed. Once you get the clutch side cover off you will see what all has to come apart before you can get at the kickstarter. Its a job but it goes back together easier then taking it apart. Make sure you have new gaskets before tackling this job. Try to remember where everything goes when putting it all back together can be a pain. Maybe take photos as you go along or find some diagrams of the engine internals.
kjhansen52
New Member
Wow. Why does the cylinder head have to come off? Clutch is automatic, does that make a difference?
Keith
Keith
The cylinder head has to come off so you are able to split the engine cases. Like I said before replacing the kickstarter is a major job. You basically have to dismantle the entire engine to replace it. That is why you see so many kickstarter levers welded to the shaft. The owner discovers what all has to be done and decides it just isn't worth it or does not have the mechanical skills or patience to tackle the job. Its up to you to decide whether its worth it or not. A regular mechanic will probably charge 250 to 350 bucks to replace it.
Trail70man
Member
delladog
What did you do with your old motor?
What did you do with your old motor?
ez50
Well-Known Member
Don't be intimidated it's really pretty easy. I did mine with a shop manual and pics along the way. Flywheel remover, snap ring pliers and an impact screwdriver were the things other than wrenches you'll need. I can't forget the clutch nut socket too. Clean out the clutch and put in all new snap rings and thrust washers while you're in there. Go for it:4:
Pretty straight forward in the Clymers manual. Just follow the step by step chapters and before long it's all apart. Might as well throw some new rings on it while your there. Dratv has a fresh up package for 110 bucks that gives you a new piston, rings and a new head! Not a bad deal. This site can help you through out all of this process. Awesome knowledge on this site.
brian
brian
Once the piston leaves the cylinder it will need to be lightly honed, at the very minimum. Either leave the piston in place or pull two cylinder studs on the same side and you can split the cases with the piston left in place. Frankly, this is a good time to go through the engine. If you are capable of doing the teardown & reassembly, then you should be able to return the motor to mechanically new condition for around the same price of a PRC copy.
Trailbikes and dratv both sell decent bore-up kits and the cost is about the same as having your existing cylinder bored & honed, plus a piston kit. Those "too-good-to-be-true" dratv stock-type replacement heads are cheezy and have been known to have oil-control issues. A valve job shouldn't cost more than about $50, plus new valves & seals. You'll likely find a worn intake valve in yours.
The kickstart shaft is cheap enough. Replace the cam chain & plastic rollers, the clutch friction discs, seals, case & clutch cover screws, and any C-clips that were removed and for probably less than $350 in total parts (and valve job), you'll have returned your motor to factory-fresh mechanical condition.
Trailbikes and dratv both sell decent bore-up kits and the cost is about the same as having your existing cylinder bored & honed, plus a piston kit. Those "too-good-to-be-true" dratv stock-type replacement heads are cheezy and have been known to have oil-control issues. A valve job shouldn't cost more than about $50, plus new valves & seals. You'll likely find a worn intake valve in yours.
The kickstart shaft is cheap enough. Replace the cam chain & plastic rollers, the clutch friction discs, seals, case & clutch cover screws, and any C-clips that were removed and for probably less than $350 in total parts (and valve job), you'll have returned your motor to factory-fresh mechanical condition.
kcjones33
Member
Get the manual and take your time, you'll find lots of other suprises (opportunities) when you get it apart: Piston, cylinder hone, oil pump gear, timing chain, valve job, clutch (clean and replace), clean oil filter. "racerx" gave a much better detailed description.
Good Luck
Good Luck
Attachments
Last edited:
knucklebuster2
Member
kickstart
Good advice fromevery one here.Breakdown motor and have a better understanding of how it works,very few special tools needed.When I do a motor like this I buy double the parts and keep them onhand .Today I replaced a kickstart shaft and reassembled in the afternoon,Just take a lil practice,Go for it:41:
Good advice fromevery one here.Breakdown motor and have a better understanding of how it works,very few special tools needed.When I do a motor like this I buy double the parts and keep them onhand .Today I replaced a kickstart shaft and reassembled in the afternoon,Just take a lil practice,Go for it:41:
Whwre
Where did you get the manual with the pictures, I need to do this job, all the help I can get is good
Where did you get the manual with the pictures, I need to do this job, all the help I can get is good
