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Suzuki ds 80 kickstart shaft

Will soon be replacing my ds 80's kickstart shaft soon, I have never done one of these before, is there any tips or any info that may help me out? How difficult are they to do? Anything would be appreciated.

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Be sure to get a good look at how the return spring is installed on the old shaft when you remove the cover. Also, be sure to clean all the old gasket material off the case and cover before installing the new gasket.

Posted on Jul 27, 2013



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SOURCE: How do you remove the kickstart shaft from a1984

Just remove the kick lever then remove the right side cover. This will allow access to the kick start mechanism. Please rate my answer. tombones49_4.png

Posted on Aug 14, 2011

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How do you remove the kickstart shaft from a1984 Suzuki ts185? Is it possible from kickstart side of crankcase or does crankcase need to be split to access from other side?....

Just remove the kick lever then remove the right side cover. This will allow access to the kick start mechanism. Please rate my answer. tombones49_4.png

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I just bought an 1987 Yamaha TT350 dirtbike. is it a 2 cycle and how do i change the kickstart shaft

Hi, a yamaha TT350 actually has a 4 stroke engine. To replace the kick starter shaft, You need to remove the crankcase cover on the kick starter side of the engine..
The clutch basket etc will then have to be removed. '
You then use a set of needle nose pliers to unhook the kickstarter return spring from its post in the crankcase.
Release the return spring and allow it to relax. Then rotate the kickstarter assembly counterclockwise by hand , and remove the shaft assembly from the crankcase. Reverse this process to refit.
You can buy cheap workshop manuals for the yamaha XT/TT 350 models. Clymer manuals make them, there are usually good second hand ones on ebay etc,
the XT/TT350 workshop manual number is
These workshop manuals are a "must have" when working on bikes or cars etc, and by following a manual, at least you'll know that the job has been done safely and 100% correctly.

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Iv'e changed heaps of these.Follow these steps taking carefull note of where & how everything goes to make it easy to put back together. make sketches if necessary.
  • Drain the coolant & engine oil
  • Remove the hoses that go to the water pump
  • remove the waterpump cover
  • remove the impellor
  • remove the kickstarter
  • remove the clutch cover & locating dowel pins if they are still in the clutch cover(if they didn't stay in the crank case)
  • the water pump seal is a (ceramic) two piece unit
  • remove the ceramic disc & rubber holder from the back of the impellor
  • remove the impellor drive shaft from the clutch cover
  • behind the impellor drive shaft there is a small bearing. To remove this I heat around the alloy of the bearing with a heat gun (or butaine gas torch,if using an oxy torch use a small tip & take care to heat evenly & not melt anything/or heat in an oven to 80 to 100 degrees max)Use welding gloves to handle the hot clutch cover)
  • turn the cover over & whack it down on a flat piece of wood(9 times out of 10 this is enough to shock out the bearing
  • remove the back-up seal from behind the bearing you just removed noteing the direction it was facing(for reassembly)
  • now using a suitable drift,knock out the other half of the mechanical seal
  • scrape all the gaskets & clean the parts
  • check the impellor drive shaft to make sure the shaft is smooth & dosn't have any groves worn in it.If it does you'll have to replace it
  • I always fit a new impellor bearing & back-up seal & new gaskets when doing this job
  • reassembly is reverse of removal noting the following
  • to install the bearing & seals use a socket that matches the OUTSIDE diamiter of them so you don't damage them.To install the rubber cup & ceramic washer into the impellor DON'T use a drift just push them in by hand
  • apply some grease to the impellor shaft before installing it
  • Apply some soap to the ceramic disc before re-fitting it
  • to install the clutch cover, if it won't go on at the front near the impellor, turn the impellor shaft to engage the gear
  • refit kickstarter,waterpump cover,hoses
  • re-fill radiator with fresh coolant
  • re-fill gearbox with fresh gearbox oil
That just about covers it all
Hope this helps you
Regards Andrew Porrelli

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1 Answer

My 125dt dosent sart or kick sart,the gear inside have a bushing in shafting?or it was broken..

Common cause of kickstarter not engaging(I am guesing that this is your problem) is a broken spring on the kickstart mechanism,or that the kickstart idler gear cerclip has fallen off(this allows the idler gear to move forward on the shaft & thus won't allow the kickstart gear to transfer drive to the clutch hub).Remove clutch cover, put kickstart lever back on shaft spline,activate kickstart lever by hand(easier with sparkplug removed+in neautral)as kickstart lever moves down 90 degrees the gear on the kickstarter mechanism should move out to engage with gear next to it(kickstart idler gear).If the gear on the kickstarter mechanism dosn't move outward it has a broken spring on the kickstart mechanism.replace spring and all should work.(if the spring is broken you need to try find the broken piece with a magnetic pick-up tool as the broken part can cause further damage if not removed)To do this job I highly recommend you first purchase a workshop manual which will guide you through these processes.After all a manual is the most valuable tool in your tool kit.

Nov 17, 2009 | 2003 Yamaha YZ 125

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Suzuki ds 80

Kick Starters on 80CC machines are almost universal. You can look for a Honda or Yamaha and they should fit just make sure that the fitting is the same. Try to expand your search for Suzuki kickstart. good luck

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Suzuki tsx 50 motor cycle - kick start problem

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