Allen,

Thanks for the reassurance on the bolt/spline thing.

It's fixed and I have to say, I'm ashamed. I went out and took a triangular file and cleaned up the grooves. The kickstart itself was equally smoothed and so I probably wasted my time. I drilled out the snapped end of the bolt and then oversized the hole so I could up the size of the bolt and put a nut on it rather than thread into the kickstart. Then, I used a dremel disc to remove material on both sides of the gap. The only thing I'm proud of is I kept the original pin the PO had used. It fit tight and I had to beat it in as much as it took to beat it out. Then I tightened the pinch bolt with extreme prejudice. It's very solid now.

The Green Machine still needs two helicoil repairs on the shift side of the footpeg mounts. The Red Rider has three good bolts and needs a fourth that it will not soon get. If there's one thing I hate on these bikes it's fitting the pegs and bash plate. Battery.... There's room in the guts of these things for a 8amp battery and the Green Machine's been running on it fit loose. I fit the battery tray that Beatrice sells and did a great job locating where the hole for the bolt on the bracket needed to go. It won't allow for the monster battery and I'll be going back to a 5.5amp unit though the thought of cutting a hole through the cover for the monster battery to stick out did cross my mind.

I took all four running bikes for a spin early this afternoon. Some loser kids down the street felt the need to shout their lack of appreciation for the Green Machine. No matter. They were on foot. And the next bike I rode by on was the HD FXSTDIS...with a hard roll going and the pipes screaming. Children should be taught respect.

Last Edited By: mrmiji Feb 27 11 3:08 PM. Edited 2 times.