AboutBill Silver Expertise Need help with vintage Hondas from the 1960s? I am an expert with 250-305cc bikes in particular and most all of the other pre-91 models, in general. I do NOT claim to have a great deal of experience on Gold Wings, Cruisers, ATC/ATVs and dirt bikes.
Experience I have owned/ridden/maintained Honda motorcycles for 35 years. I have written five books on Honda repairs and collecting. I was a service manager for two Honda shops back in the 1980s.
Organizations VJMC (Vintage Japanese Motorcycle Club) of North America
Publications VJMC newsletter, as editor for two years and as contributing editor currently.
Question Dear sir,
I am restoring a 1995 Suzuki DS80 motorcycle for a 4-H project (I am 12). The kick start shaft broke, and my dad got me a new one. We took off the right side plate, but we can't get the old shaft to slide out. Is there something else we need to do?
Thank you very much.
Tommy
Answer Tommy, you are in for a lot more work then you planned....
The kickstarter shaft/gears are all locked into the engine cases. This is a motor tear-down project. The engine cases are split vertically, so you have to pull the top end off (cylinder head, cylinder) then pull the clutch stuff out and then split the engine cases. You will need a flywheel puller special tool, at the least. I don't know if the later Suzukis need a case splitter tool or not... This is not my brand, so don't have further details on that procedure. Time to shop for a shop manual.
