Front Left
Left Side
Right Side
Chain Guide
Flywheel Weight
Pipe 1
Pipe 2
Pipe 3
Pipe 4
Pipe Defect
Tank and Plastic

Kick Start Lever

Here are some pictures of my modifed kick start lever. It had developed some severe wobble. Luckily the steel pin was still fairly round. Only the aluminum socket was distorted. I mounted the kick start lever in the milling machine and slowly plunged an end mill into the socket. This trued it up and provided the clearance to press in a brass bushing. The window machined in the side of the bushing allows the kick start locking bolt to still function. A hole was also drilled for the spring loaded lock ball. Here's what the assembly looks like. The camera really makes this look ugly. It looks much better in person. More importantly it came out fantastic and is tighter than new.

Gear Shift Lever

Of course with the kick start coming out so good, I HAD to fix the serious case of tip wobble in my gear shift lever. After grinding out the pin, I could see that the steel pin had caused the hole in the aluminum lever to be elongated. This allowed the tip to pivot and wear out the top land on the lever. I started by drilling the hole in the lever till it was round. Then I had to drill the tip to match. Next came machining a new pin. I made the pin oversized, so that it will no longer pivot in the lever. Now the tip pivots on the pin. I also made a thin brass shim to act as a wear plate between the tip and lever. Rather than peening the pin onto the lever, I threaded the inside so it can be disassembled again. Here's an exploded view of the parts and the assembly.