Kickstart shaft too short?????!!!

[Luke]

I have what I believe to be a S3 LI/SX/TV side casing and a S3 LI/SX/TV kickstart shaft! When I fit the kickstart shaft to the side casing I only have enough of the kickstart shaft sticking out/protruding to fit the circlip only and no room to fit the kickstart shim!
The mating faces of the inside of the side casing and the kickstart shaft where it rotates are fully meeting, so there is no gap there!
I am assuming that if the kickstart shim is left off, I will damage the kickstart seal when starting the scoot??
Any feedback/solution much appreciated!!!!!
Cheers
Luke

[rossclark]

There was a modification to remove some from the inside of the casing, could be a post mod shaft and a non modified casing?

[Dimitrios_231]

GP shaft with earlier S3 side cover,MB has a good skimming tool for this job.

[HxPaul]

Check that the kickstart shaft bush that fits in the casing is flush with the inside of the case,if it sticks out just a bit it can cause the problem that you're describing.

[Adam_Winstone]

Yes to all of the above.

[Luke]

Kickstart bush in casing is flush so I may have to get casing skimmed!
Thanks for help
Cheers
Luke

[MK Monty]

I did my last one with a router, used a strait cutting bit and trimmed it a bit at a time. The aluminium is quite soft and it was done hand held without a problem. I pushed the inner bush through then trimmed it with a flap disk as is a a bit harder. I have used a flap disk in the angle grinder and thats worked fine as well. Try and borrow a tool if you must but you will not need it again

[Luke]

Good idea!
Cheers Monty