LCGB Forums

Hello all. Are there different sized kick start shafts in the part where the plunger fits? I have bought a new shaft after mine broke and I have assembled everything. It all moves freely until I join the side case to the chain case and tighten up. When I depress the kick start lever, the end of the shaft is rubbing and the lever sticks. I undo the nuts and the lever frees up again. The shaft now has a slight indentation and bare metal on the end. Series 3, 5 speed Cyclone gearbox. Cheers

Shafts do vary a bit especially SIL or other indian knock off's. You dont say exactly where its rubbing but its oks to remove metal with a dremel or possibly use a thicker gasket or even 2 gaskets. I THINK MB sell thicker gaskets.

Revvers wrote:Hello all. Are there different sized kick start shafts in the part where the plunger fits? I have bought a new shaft after mine broke and I have assembled everything. It all moves freely until I join the side case to the chain case and tighten up. When I depress the kick start lever, the end of the shaft is rubbing and the lever sticks. I undo the nuts and the lever frees up again. The shaft now has a slight indentation and bare metal on the end. Series 3, 5 speed Cyclone gearbox. Cheers

Extremely enough common problem as correctable as coaster says in his excellent reply. In any case, these days I think it better to fit as thick a chain case gasket as can be bought simply because they tend to seal far better due to greater ‘compliance’ & be re-useable when fitted with faces greased up. Just fitting one might be all you need to fix your issue….