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Replace Kick Start Shaft

13K views 5 replies 4 participants last post by  DrBob  
#1 ·
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?
 
#2 ·
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.
 
#5 ·
Man! That is music to my ears.:D

The shop wanted $450 labor + $40 part to do it.:shock:
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.