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Converting Electric Start back to Kick only

Posted: Sun Mar 06, 2016 8:29 pm
by WJS
Hi I am part way through converting my electric start 500 classic back to kick only specification to take advantage of the 5 or 6 kg weight saving this brings. Have stripped down and removed the electric start inner chain case and am now looking at the subtle differences with the kick only inner case. Seems like the standard inner case needs tabs to retain the crankshaft oil seal and hold the case on studs. The electric does not have these but has countersunk setscrews to retain the case and a slightly wider shoulder around the seal. I know I will have to drill and tap the crankcase to retrofit the standard inner case but are the tab retainers really necessary? Seems odd that one model would have them but the other not.
Admittedly there is not much room behind the engine sprocket on the e. start but is the crankshaft oil seal really likely to work loose? On either model?
Anyone done this conversion?
Cheers

Converting Electric Start back to Kick only

Posted: Sun Mar 06, 2016 11:24 pm
by Cafeman
Likely not needed, Loctite 609 retaining compound should do. Those tabs are cheaper than the Loctite though. The right way would be to put the tabs in and forget.