Defect new part

[Tee-Why]

I found out today the hard way that the new TY175 kickstart axel or output shaft is not what it seemed. When assembling the spring and gear mech onto the new shaft, the groove for the small circlip is missing???????

This item:
http://www.cmsnl.com/products/kick-axle ... 251566001/

Bit of a setback, need it this weekend, dont know if I will bother with Yamaha due to buying it last year and lost the receipt, so will try and get a machinist to do the job, along with another job to make a small bush for the gear lever cover.

[TYYamFan]

Hi Roger,

I had the same problem last year. After discussions with the walking TY encyclopaedia (D.L.) I just assembled as usual but shimmed the shaft so that there was just perceptable end float and all is well, I mean it can't fall out can it?!!

Mark - WA

[Tee-Why]

All sorted, got a groove cut on the shaft.

The same prob with Mike K.'s bike on the weekend had the very same problem after borrowing a shaft of Leo before the event. Must be a common flaw in the new replacement part.
Both options work, what Mark suggested by shimming and getting a circlip groove cut on a lathe.

The other job I had done at the same time, was a bronze bush made and inserted into the small gear lever cover, with a new seal. It has made a huge difference and is about 90% better, no false neutrals, heaps cheaper to pay a machinist $80AUD than the UK kit for 140GBP.