Kickstarter project & other reassembly

The kicker shaft is mounted and reassembly is to begin.

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Last week we wanted to focus onto the actual reason why we disassembled the engine of my Z440LTD. As you can remember, the Z440 was never built with a kickstarter. And as its older ancestor Z400 used most of the same engine parts and came with a kicker, my idea was born.

All the drillholes in the crankshaft case are in place, the complete kickstart shaft including all parts, springs, lockrings are mounted and the simple and clever mechanism is understood now (my co-wrencher and I had no idea what the trick in it was).  Only the necessary drillhole for the starter shaft to pass the crankshaft case lid needs to be made including a seat for the oilseal. We’ll work on that.

Meanwhile, reassembly began with polishing the valve seats, remounting the valves including new valve shaft oil seals. Assembly is much easier with a special valve spring tensioner — and helping hands of my co-wrencher.

Hang on for a sec. I’ll be back.

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