experiment70 Posted September 23, 2010 Report Share Posted September 23, 2010 I broke the kick start gear in my '07 300 Pro, and am having a miserable time getting it back together. I found the technical bulletin about indexing (www.trialspartsusa.com/diagrams/Pro_Technical_Bulletin_June_8_2010.doc), and have the shaft itself back together. The problem is getting the shaft back into the cases. I have watched Jim Snell rotate the assembly one time counter clock wise (www.youtube.com/watch?v=A80n7zq80n8) and drop it in, but I can't do what he does; I keep getting the spring caught behind the whole assembly, which doesn't allow me to fit the shaft into the blind hole it's supposed to rotate in. When I swear loudly and take everything back out, I can see that the spring has actually bent at the long straight section that fits into the case. What am I doing wrong? I really want to ride this weekend, and I'm getting frustrated. Thanks in advance for any help, Forrest Quote Link to comment Share on other sites More sharing options...
lowbrow Posted September 23, 2010 Report Share Posted September 23, 2010 Been there! Done That! You're not necessarily doing anything wrong. It can be a right fiddle and needs lots of patience. Watching Jim Snell make it look so effortless just makes it worse! Keep calm and carry on. Good luck. Quote Link to comment Share on other sites More sharing options...
mclarke Posted September 23, 2010 Report Share Posted September 23, 2010 David wot are you doing on here at 3.20 in the afternoon .You need to get a proper job ,and are you riding this weekend? Quote Link to comment Share on other sites More sharing options...
lowbrow Posted September 23, 2010 Report Share Posted September 23, 2010 Michael, thank you for your most sincere concern. Truth is I've been so unsettled worrying about what happened to the back mudguard on that Greeves when Phil Disney was riding it that I haven't been able to work since! Quote Link to comment Share on other sites More sharing options...
mclarke Posted September 23, 2010 Report Share Posted September 23, 2010 I thought you were gasgas through and through David,i wouldn't have thought you would look at video for greeves let alone be concerned about the brittle rear mudguard. You must be softening in you old age. Quote Link to comment Share on other sites More sharing options...
mclarke Posted September 23, 2010 Report Share Posted September 23, 2010 It's no good i can't wait for your reply any longer David, i must go down to the motor club now the draw is just to strong ! Quote Link to comment Share on other sites More sharing options...
experiment70 Posted September 24, 2010 Author Report Share Posted September 24, 2010 Been there! Done That! You're not necessarily doing anything wrong. It can be a right fiddle and needs lots of patience. Watching Jim Snell make it look so effortless just makes it worse! Keep calm and carry on. Good luck. Thanks for the encouragement. Any tips for keeping that spring from getting stuck between the case and that aluminum top hat piece? And any tips for increasing my patience? It's running low... Forrest Quote Link to comment Share on other sites More sharing options...
experiment70 Posted September 25, 2010 Author Report Share Posted September 25, 2010 I finally got it installed today; I built a little tool out of a piece of spring steel that helped me pull the kick start spring up when it wanted to come off the AL top hat piece. It looked like such a simple job... Forrest Quote Link to comment Share on other sites More sharing options...
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