TOPIC:

Got a kz400 project that I'm swapping a 440 motor into and I want to keep the kicker. I've got the cases split and have all the kicker parts swapped over but when I button it up the crank won't spin and all I can see causing it is the kicker gear. I tried swapping out the first gear cog from the 400 since theyre different, but it won't work on the 6spd 440 trans.

So is this possible? Do I need a different size kicker gear? From what? The 6spd trans is more important than a kick starter but having both would be the best.

You have to use the "79-"80 KZ400 parts for a direct bolt in replacement.
Or do like I did and machine both first gear gears down. The trans shafts are the
same size and spline.



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Cool, cause I think I have those too. Do I need just the kicker parts to do this or the first gear stuff as well?

So the 900/1000 kicker gear works if you pull the bushing from the 400 gear and fit it in the 900 gear so that it fits the smaller shaft. And then grind down the spacer to make up for the gear being wider. Seems to be working on the bench, we'll see what happens in the bike.

Mercury Kid wrote: So the 900/1000 kicker gear works if you pull the bushing from the 400 gear and fit it in the 900 gear so that it fits the smaller shaft. And then grind down the spacer to make up for the gear being wider. Seems to be working on the bench, we'll see what happens in the bike.

Where did you get this 900/1000 idea?


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It was what I had available. Figured it was worth a shot