kick starter pin removal

[aka HAWG]

it was a nice day today so I thought it would be nice to run the indian up and down the street today before the imfamous snow start to fall and ruin riding season

while kicking it over the bike decided to backfire half way through a kick and the shaft that holds the kickstarter sheared off at the frame - I loosened the bolt and tried to remove the remaining shaft - It would not move.

not wanting to wail on it just yet with a big hammer I thought I would ask first - is the shaft just a tight fit or is it a press fit into the frame????

aka HAWG

[exeric]

I've never broken that shaft but I have worked up a sweat getting one out of the frame. They should be a finger press to a light press fit so they don't wobble. Of course rust is going to make them superman tight. My '40 frame has an opposing hole so you can use a drift to beat it out. If your frame doesn't have a hole, I would suggest you drill one. If you don't want to do that, you could drill and tap a hole in what's left of your shaft and use a slide hammer to yank it out. I hope it doesn't get too ugly for you.

[aka HAWG]

thanks for the input

My frame has the opposite hole - I tried gently to punch the shaft out and it did not move - thus the asking prior to wailing

aka hawg

[redfred84]

kicker pin removal

It's always been ugly in this area for me. Heat & beat is the method I resort to.
Rots a Ruck,RF
Never heard of shearing this pin off though.

[aka HAWG]

here is the pics of the damage

[twistedchout]

Kicker pin removal

Hi, I had a bit of the same problem until I discovered that the set screw was replaced with a hex bolt hidden in the dirt. Guess you checked that?

[aka HAWG]

my frame is very clean ( no dirt / oil ) I do see the set screw/bolt thanks for your input
aka HAWG

[Bills37]

This might be a little out of date but I will post it anyway.

First find a flat washer with a hole slightly smaller than the diameter of the shaft.
Plug weld washer to center of shaft
Find nut the that will thread onto a slide hammer.
Center nut on flatwasher that you welded to shaft and weld nut on outside.
Allow to cool and thread slide hammer on and remove broken shaft.

[aka HAWG]

thanks for the input - have not had time to work on bike as of yet. just after Xmas it turned cold and snowy and has not let up yet.
an un-insulated 3 car garage to work in ( I do have a wood stove in it ) it is hard to find the warmth and time to start working on it - but it will have to be done soon

aka HAWG

[cdf6333]

There are a bunch of sizes of that shaft available. Measure carefully BOTH ends. The most common one I've seen original Indian is .030 OS on the frame end. Measure the ID of the hole at a bunch of clock positions and use a shaft that's .002 to .005" bigger. Shafts are available that have an offset shaft too. By rotating the shaft, kicker gear engaugement can be changed. Believe me though, your problem is a good one. Having a loose shaft, with the resulting egg shaped hole, is a lot worse!

[aka HAWG]

started to try to remove pin this morning - tried to drift the pin out through the backside hole - the frame section that holds the pin is not drilled all the way through - can't remove this way

drilling medium size hole and tapping it to put a bolt in to attach to slide hammer - that was a no go, pin did not move

tried heat and slide hammer - no go, pin did not move

drill larger hole , re-tapped, heat and once again slide hammer - pin does not move

now drilled out to largest drill bit I own ( that is not too big for frame hole ) and slowly using a grinding stone to remove the remaining steel - slow process but it is working

aka HAWG

[exeric]

I feel for you HAWG. It's jobs like that the make people cynical and bitter. However, when you do get it out and put a new pin in, you'll feel great.

[fillibuster]

I like Bills37's method of welding to the end, but go for as large a washer and deep a nut as you can, and go for the hardest threads you can.
The welding heat always results in a little shrinking of the welded material. Since it cannot swell much it must cool to a smaller dimension which is what you're after. .. I still believe that you will need to drive it out from the primary side, though. So place something heavy against the frame on the right side to eliminate the bounce, or flex that the frame my have when slamming from the primary side. Have a buddy hold a rock bar against it. Wear the safety glasses. ... may still have to heat the outer, .. keep a fire extinguisher within reach. .. hope your luck is better than all that.

[aka HAWG]

yippie it is out

the hole on the back side imo is too small to drift the pin out should almost be 1/2 inch but then the frame would be weak

sanded 3/4 or more of the pin and decided to push it into the frame to see if it moved - it did, loosening whatever hardened in the frame section so that it appeared to not have a hole all the way through

going back throught the rear hole pushed the remainder of the pin out - tomorrow try to get the hardened gunk out from the lower seatpost hole - I guess it is just dirt and grease from the last 50+ years - or I hope it is that

next week order a new pin from jerry greer

want to ride at oley

aka HAWG