Removing a Motorcycle Kickstart Shaft Seal
Step 1. Check for a punch mark on the kickstart shaft next to the split in the kickstart arm, which indicates where the kickstart arm should be positioned. If there isn’t a mark, make one with a marker pen to allow you to position the kickstart arm correctly when you reinstall it.
Step 2. Remove the pinch bolt holding the kickstart arm to the kickstart shaft.
Step 3. Slide the kickstart arm off the kickstart shaft. If the arm is too tight to move, use a flathead screwdriver or chisel to widen the split in the kickstart arm and loosen it.
Step 4. To remove the old kickstart shaft seal, try one of these methods:
- Screw a drywall screw into the kickstart shaft seal, then grip the screw with a pair of pliers and pull the seal out from the crankcase.
- Slide a pick tool around the outer edge of the kickstart shaft seal and gradually pry the seal out from the crankcase.
- Press a punch tool into the kickstart shaft seal beside the shaft itself and lever the seal out from the crankcase.
Installing a Motorcycle Kickstart Shaft Seal
Step 5. Clean the crankcase and kickstart shaft with contact/brake cleaner.
Step 6. Lightly grease the kickstart shaft and the inside of the new seal where it contacts the shaft.
Step 7. Press the new kickstart shaft seal into the crankcase. Use a socket with a diameter that’s just under the diameter of the new kickstart shaft seal, and gently tap the new seal into the crankcase.
Step 8. Reinstall the kickstart arm with the split in the arm aligned with the mark on the kickstart shaft.
Step 9. Make sure the kickstart arm is set at the correct depth on the kickstart shaft so the pinch bolt can slide through the channel in the shaft. Next, reinstall the pinch bolt, then tighten it completely and you’re done.
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