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Post subject: Modification on kick start arm from RD350 to RD500 kicker
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Dylan  Find me a Road! Joined: 11 Nov 2004 Total posts: 18 Location: South Germany |
Hi together,
i know there are some specialists in this forum who use a RD500 kicker on a RD350 (can't find the right topic).
Does anyone can tell me how i can modify easyly my RD350 kick start holder to mount a aloy RD500 kick start arm.
As you know the RD500 holder bolt are longer than the RD350 holder bolt.
Thanks
Dylan
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Posted: Tue Feb 27, 2007 11:35 am
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| Rich |
When I did mine, I modified the 500 lever to fit the 350 knuckle. All you need to do is shorten the mounting boss (the bit with the hole through it) at the base of the 500 lever. I cut a slice out with a hacksaw and filed the rest, it could be done more easily if you have access to a milling machine. The hole bore is the same size as the 350 knuckle. I'll try and post a pic later 
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Posted: Tue Feb 27, 2007 11:41 am
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DylanFind me a Road! Joined: 11 Nov 2004 Total posts: 18 Location: South Germany |
Thanks Rich for the quick answer 
A pic would be nice and helpfull. Do you think the material thickness are strong enough if you cut them down to nearly 60% (it's only aluminium).
I prefer to change the knuckle shaft, but i don't know the best way to do that. The hardness of the knuckle material are quite high  and therefore it isn't easy to rework them.
Cheers
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Posted: Tue Feb 27, 2007 12:40 pm
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oldelsieboy All-gear Wheelie! Joined: 06 Jan 2004 Total posts: 1686 Location: Surrey |
Hi Dylan
I fitted my 500 kicker by welding the splined collar into the main kicker knuckle.
I then drilled & tapped the end of the kickstart shaft fitted to the motor to accept an M8 bolt .
The modified 500 kicker is then slid onto the shaft & held in place by a bolt & washer tightened into the end of the shaft.
http://img.photobucket.com/albums/v155/oldelsie/DSC00069.jpg
http://img.photobucket.com/albums/v155/oldelsie/DSC00068.jpg
OEB
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Posted: Wed Mar 07, 2007 4:13 pm
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DylanFind me a Road! Joined: 11 Nov 2004 Total posts: 18 Location: South Germany |
Hi oldelsieboy,
many thanks for the very good idea ! Looks very nice, and i think a good solid solution.
Due to the days without any reply i tryed and finished a own solution (take a look on the attached pics).
Have drilled a center hole 8H7 (tight fit) in the 350 knuckle shaft. Have cut down the 500 knuckle shaft and manufactured a 8,02 mm pin by turning. After that i fixed both parts together with loctite + pressing. Now i have the possebility to fit the original 500 kicker (without mods on the aloy material) to the 350 knuckle and it seems to be a usefull solution. I hope it will works a long time 
http://img262.imageshack.us/img262/2829/rd500kickerxj0.th.jpg
http://img511.imageshack.us/img511/9894/y001wv4.th.jpg
http://img174.imageshack.us/img174/7976/y002xn5.th.jpg
[img][/img]
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Posted: Wed Mar 07, 2007 5:52 pm
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powervalve 350 Throttle Demon Joined: 04 Aug 2003 Total posts: 3070 Location: Hull UK |
You can always get MR KIMBER to supply.He has loadsa new stuff on his updated site!
http://www.nkracing.co.uk/
kickstart on http://www.nkracing.co.uk/nkr06.html
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Posted: Wed Mar 07, 2007 6:31 pm
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Froth Sunday Rider Joined: 22 Apr 2004 Total posts: 46 Location: Nelson New Zealand |
Since the 500 kicker is so hard to find and expensive if you do, has anyone fitted a kickstarter from another bike, like from a dirtbike? I'd be interested to find out if something from a YZ or KX would fit....
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Posted: Thu Mar 08, 2007 10:37 am
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BareAll-gear Wheelie! Joined: 28 Jan 2006 Total posts: 1836 Location: Vancouver Canada |
I'm wondering WHY some one would bother doing this.. Just checked and a Brand New Yamaha 350 kickstart assembly (the whole damned thing) costs $61 retail .. that's like what ?? 30 GBP's
Seems a lot of agro for a small savings.
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Posted: Sat Mar 10, 2007 3:12 am
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nokturnal Powerband Master Joined: 22 Jan 2004 Total posts: 788 Location: Toronto, Canada |
| Bare wrote: |
I'm wondering WHY some one would bother doing this.. Just checked and a Brand New Yamaha 350 kickstart assembly (the whole damned thing) costs $61 retail .. that's like what ?? 30 GBP's
Seems a lot of agro for a small savings. |
because they look cool 
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Posted: Sat Mar 10, 2007 5:44 am
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FrothSunday Rider Joined: 22 Apr 2004 Total posts: 46 Location: Nelson New Zealand |
because they look cool [/quote]
Wot he said
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Posted: Sat Mar 10, 2007 9:56 am
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PanPowerband Master Joined: 19 Jun 2005 Total posts: 562 Location: Liverpool UK |
| Froth wrote: |
| Since the 500 kicker is so hard to find and expensive if you do, has anyone fitted a kickstarter from another bike, like from a dirtbike? I'd be interested to find out if something from a YZ or KX would fit.... |
By the look of the one on the NK site, thats what he's done.
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Posted: Mon Jun 02, 2008 7:38 pm
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