Forum

[Barry N]

I am aware that, despite identical part numbers for the driveside mainshafts, there is a variance in the fit of the splines of an electric start engine sprocket versus a kickstart-only sprocket. My bike started life as an electric start (Sixty5) which I converted to kickstart-only, but the new KS engine sprocket was a sloppy fit on the splines (unlike the original ES sprocket, which was snug) but I used it nevertheless for a few thousand miles. However, now that I am doing a major rebuild, I want to put this right. One option that I have heard of, is to have the starter gear removed from my original ES sprocket. That would be the perfect solution, but since it is hardened steel, it would be a specialist job (ie. surface grinder or special cutting tool?). Or is there possibly a kickstart engine sprocket available which would fit more snuggly? Has anyone successfully overcome this problem, or can anyone recommend a capable machine shop for removing the starter gear of my original sprocket? Cheers!

[Paul M H]

When I converted my old work Bullet to kick start only I used The one supplyed In the Kit from Hitchcocks and it fitted perfect on the splines. May be you were just unlucky with manufacturing tolerences. Lets see what others have found

[Norm]

Barry,
No problems just cut it off carefully with a grinder I have done a number of them, 5 minute job

[Barry N]

What sort of grinder Norm? Do you mean a cutting disc on an electric drill or an angle grinder - or something else? I'd certainly like to give it a try. Thanks!

[Norm]

Barry,
You might be able to do it with a grinding disc in a drill , but just an ordinary 4 inch angle grinder is fine, hold the sprocket in a vice and just hack it off, it doesn't have to be perfect because that section doesn't have to mate up to anything, and it isn't that thick.