Kickstart/layshaft bush

You can do it with bits that you probably have in your odds and sods box. I took a good stout waster with the same OD as the bush, filed two flats on opposite sides so as to allow the washer to pass through the bush. I then took a length of studding and a couple of nuts. I placed a lump of blue tack in the bottom of the kickstart hole beyond the end of the bush. Then I used this to position one of the nuts, passed the washer on its side through the old bush , passed the studding through the bush and screwed it into the nut. I then pulled the studding up so that the washer now located on the bottom of the bush, took a space larger in ID than the OD of the bush flange,( I used a socket), then fitted a second washer and nut to the studding. I then took up the slack by tightening the top nut and by tightening this nut further was able easily to extract the bush. Replacement used the usual freeze the bush and heat the kickstarter.

Good luck.

If you look at Mick Hemmings gearbox video, he uses an old tap to extract blind bushes. Just screw the tap into the bush, clamp the tap in the vice and use a hammer to knock the item off the bush.

Previously alan_sessions wrote:

If you look at Mick Hemmings gearbox video, he uses an old tap to extract blind bushes. Just screw the tap into the bush, clamp the tap in the vice and use a hammer to knock the item off the bush.

Is this the bush that looks like a huge steel wedding band? It is the bush Mick Hemmings does not replace in the video because they always have a certain amount of slop even when new.

Previously robert_tuck wrote:

No ,thats in the cover,we are talking about the bronze bush with shoulder that fits inside the kickstart shaft and supports the end of the lower shaft(layshaft). In fact I think the problem is with the cam plate being incorrectly timed by a tooth. I did not think it possible to get 4 gears if not timed properly,but it seems you can.

You can probably select 4 gears because the slot in the inner cover has been opened up top or bottom to allow more movement.

Hi Robert

Having just refurbished 2 Dollshead gearboxes the simplest way I found was to cut thro the wall of the bearing in 2 opposite sides of the bush using a standard hacksaw blade; you will not damage the kickstart shaft it is far harder than a hacksaw blade. Then cut thro the flange using a small chisel in 2 posns to align with the saw cuts and 'Bob's your uncle' it will just fall out. I think trying to remove it by screwing a tap into the bush and then hammering the kickstart could end up with a broken tap to remove as well.

Derek Ambler