Kickstart ALWAYS jams, SOLVED

[jhg1958]

I know this is an old thread but I seemed to have fallen into the same trap.  After recently rebuilding the gearbox I paid little attention to the kickstart.  After all is is only a kickstart.  All was fine when the gearbox was on the bench. Now the engine is connected nobody will be surprised that the kickstart jams.

So I have the outer gearbox cover off and can replace the the pinion bush and the outer bush on the kickstart.  Without taking the inner gearbox cover off I cannot change the inner bush on the kickstart.  I am struggling to get the inner cover off.

So a couple of questions

1/ Do I need to remove the gearbox from the frame to remove the inner cover?
2/ If not, is there an easy way to separate the inner cover from the body of the gearbox?
3/ Do I really need to replace the inner bush as the previous entry seems to think the pinion bush is key followed by the outer bush?

John

[muskrat]

G'day John.
It's been a while since I did one but it would be easier with the inner cover off but I think can be done in place with an internal puller. (pic att)
To remove the inner cover the pinion nut, pinion, bush, spring and washer comes off. The cover comes off with the bearing. It may be tight on the shaft so may need a few taps on the shaft with a hide mallet and pulling on the cover at the same time.
Cheers

[sean]

These blind bearing pullers work well for bushings and needle roller brgs the other puller is for starter motor bushings but its come in handy on other jobs

[jhg1958]

Removed the inner cover and replaced the inner and outer bushes of the kickstart and the gear change lever.  Also changed the ratchet pinion bush and the problem has dossapeared.
John