Scooterotica

Has anyone got any ideas for getting the new stronger SIL kickstart shafts into Li/SX S3 casings.The bush stops the shaft going all the way through so I can't get the shim and circlip on. I know MB have a reaming toll but it's out of stock. If there's an area on the bush I could attack with grinding drill bit, the shaft will be too hard to grind.

Hi,have you fitted new bronze bushes?if not it sounds like the bush just needs tapping in flush again,saying that if you're fitting a gp shaft to an li casing then you will need to mill the casing down inside and use thicker shims on the outside as the shaft will touch the top plate on the clutch .

Dean

I've got the MB tool in stock but it's for removing alloy from the chaincase so the shaft can seat deeper to clear the clutch.

corrado wrote:I've got the MB tool in stock but it's for removing alloy from the chaincase so the shaft can seat deeper to clear the clutch.

I see, it removes the alloy from the casing not material from the bush. If this is the case I should be able to carefully get a grinder in, the only thing is that I can't see what stops the shaft sitting in for those last few MM's.

LI/SX kickstart shafts are longer and the sidecasing slightly deeper then GP. Im sure someone will pop up and say you need to use a magic nose goblin to extend a GP shaft* but i find putting the shaft in the lathe and taking a couple of mm off the back allows it to sit through far enough to get the shim and circlip on. As with most new kickstart shafts you will probably have to grind the face back to get it clear of the top plate as well.


*This is a made up scenario and should not be attempted for health and safety reasons,however if someone who spends a large portion of their life posting on internet forums suggests something equally silly then they are,of course, to be believed.

stickies book explains it i believe

The Li, Sx & GP Italian series 3 measure 67mm to the circlip groove.
GP Indian measures 65mm to the circlip groove.
So trying to fit an Indian shaft into an Italian casing requires the inside of the Kickstart boss trimmed down by 2mm so the shaft protrudes enough to fit a 1mm shim & the star type circlip & new seal, these 3 items are sold as a kit from AF Rayspeed.
Also remember to grind the axle shaft to give enough clearance to clear the clutch bevel top plate when the clutch cover is fitted!