Vintage Dirt Bike Q & A

I recently got another kick starter for one of my Elsinores. Problem is, it's almost as loose as the one I have.

Is there any way to rebuild one of these kick starters?

Thanks,
Jim

I'm betting if you remove the knuckle from the kick start lever, the hole in the lever
where the pin you just removed goes, is elongated. There is a good chance the hole
in the knuckle is too.

Some guys drill those holes out and sleeve them with a soft metal (brass, copper, etc.)
bushing that is a tight fit on the pin. I prefer to fill weld the holes then drill a new pin
hole. It's also a good idea to check the spring tension while you have it apart, replace
if neccessary.

The first method doesn't require any welding cost or skills and won't discolor the metal
neccessitating a re-chrome. The second method should be a longer lasting fix. Both
should eliminate the "floppy lever syndrome."

dogger

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1973 CR250M
1979 CR250R
1993 CR250R
2008 CR500R
2009 CR250R