2007 fe550 kick star, gear selector seal

Ive done the selector shaft seal and the wp water side seal without removing the cover kickstart should be the same

its not difficult if you are used to this kind of work but it does need some funny shaped "picks" and seal "drivers" (bent files and pipes)

removing the cover makes it easier just remember to make sure the kickstart shaft is pushed inward at all times while removing/installing the cover otherwise it needs to be reset

Hey man I replaced those seals a few months back and just took the cover straight off. Saves a lot of dicking around I think, it's much easier to work on that way.

Just be a bit careful of the water pump seals when you press the cover back on. I just lube it up with some Vaseline everytime. I have a spare pump seals but haven't had to use it yet!

bushmechanic said:

removing the cover makes it easier just remember to make sure the kickstart shaft is pushed inward at all times while removing/installing the cover otherwise it needs to be reset

Click to expand...

+1

Don't mess the kickstarter. Keep it pressed inwards if you take the cover off.

bushmechanic said:

...
removing the cover makes it easier just remember to make sure the kickstart shaft is pushed inward at all times while removing/installing the cover otherwise it needs to be reset

Click to expand...

I learned this the hard way when the kickstarter spring lost it's pre-tension just after I finished the clutch install on my 05 FE550e. Seems the kickstarter gear moved outward approx 1-2 mm. (when it's set properly the kickstarter gear lines up exactly with the intermediate gear). during the second attempt I put a shim between the clutch basket and kickstarter to hold the kickstarter in, and removed the shim just before putting the cover on.

My problem is that the cover is back on now but the kickstarter doesn't move. I'm assuming that the pre-tension was lost again. I'm thinking that the inner boss of the cover doesn't come close enough to the kickstarter gear to keep it held in place? Next time I take the cover off I'll do some careful measurements to see if I need a shim between the kickstarter gear and the cover.

Also, I think I may be missing the kickstarter shaft seal ring (part #16 on page 69 on the 2005 parts book). Can anyone tell me where this mounted (in the cover or does it sit on the shaft in between the gear and cover?) . The measurements of the seal are 18x24x4 mm, do you know what is the material? I might try making this part on my lathe.