CB72/77 Kickstart gear

[G-Man]

I've built up quite a collection of damaged kickstart gears, none of which are easily repairable on their own. The first two I looked at had complementary faults. One had a damaged gear and one had a damaged spline.

This one had a broken gear tooth.



And this one had a badly damaged spline.



I set about annealing the centres of the two shafts/gears and then drilled through the gear on the second one so that the gear dropped off of the shaft.



Next, I had to get the damaged gear off the good shaft. This was a little harder and required a trip to my mill with rotary table.



I was able to press the two good parts together to make one good kickstart gear.



To finish off, the parts will be welded, cleaned up then sent for zinc plating with my next batch

I still had a couple more with 'bad' splines so these were treated to new shafts by modifying CB250 parts to fit inside the CB72 gear. The CB250 shaft has the same spline but the diameter of the shaft has to be reduced from 18mm to the 17mm required for the CB72 part.



Here are the two 'new' shafts and their gears.




I now have three gears ready for welding up. A 'good day at the office'............




G

[Muddy]

Outrageously good work G.

I wish I had your equipment, skills and finesse.

Great job.

[G-Man]

Hi Muddy

How are things in Oz? Very sad to see all of those terrible fires.

It's good to be able to post my stuff here to share with folks. I hate to see the often used phrases on eBay "rare & unobtainable" as justification for stupid prices. There is always a way to re-purpose things.

G

[Muddy]

G'day G-man

Sorry, I missed your reply.

Yes, the fires were bad and now to be followed up globally by the big virus - tough times for all.

Keep that great work going - I'm still very envious of your skills and tools.

Regards

Muddy