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  1. #1
    Newbie
    Posts
    2

    Replace Kick Start Shaft

    I have a 1995 DS80 and I broke the kick starter shaft yesterday.
    This is an old beatup bike for my son to ride this summer and I don't want to sink much money into it.
    I can get the shaft for $39 and a gasket set for $25 from alpha-sports.

    Can anyone tell me what is involved in replacing the shaft?
    Will I have to pull and disassemble the entire engine?
    No details just an overview of the procedure.
    Should I take this to a shop and let them do it?

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  3. #2
    Just Won't Go Away !
    My Bike(s)
    several
    Location
    Buford, GA
    Posts
    5,197
    I am not familiar with that specific model, but as a general rule a kickstart shaft can be swapped by removing the side cover, and is not a major project requiring anything but basic hand tools.
    You MUST obey the pug dog!


  4. #3
    Forensic Bug Splatter Analyst
    My Bike(s)
    05 Boulevard C50 LE, 06 S40 (wife's bike)
    Location
    Lexington, KY
    Posts
    4,158

  5. #4
    Supporting Vendor
    Location
    La Quinta, Ca
    Posts
    754
    I am not familuar with that engine, but other engines that I have worked on with kick starts usually only needed to pull apart the out side case the kick start shaft went through.

  6. #5
    Newbie
    Posts
    2
    Man! That is music to my ears.

    The shop wanted $450 labor + $40 part to do it.
    That was too much for me to spend on this old bike. I payed $275 for it but now I'm thinking it wasn't as good a deal as I first thought. I ordered the shaft and a new oil seal AND a new kick lever. A previous owner welded the lever to the shaft. I think this contributed to the breakage, that and the lever not being at the right angle when completely kicked down. Instead of stopping at 6 o'clock position the lever stopped at about 7:30 which would put extra stress on the shaft. This is only my logical thinking. If I'm wrong about this please correct me.

    Thanks for the "Welcome" and the help, really.

  7. #6
    Just Won't Go Away !
    My Bike(s)
    several
    Location
    Buford, GA
    Posts
    5,197
    You'll need the cover gasket also.
    You MUST obey the pug dog!



 

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