Well after seeing a picture of prohemi500's atc 500r with a forward kick setup, i decided that i would also like to have one. My 500 has always been a pain to start. Its not that i cant kick it over, i think its that i cant kick it over fast enough. The pig would always start easily by pop starting which leads me to believe the motor just wasnt turning over fast enough. So im running a slightly larger gear behind the motor with hopes this will cure things. If it's too hard to kick over like this, there is always the decompression setup i could install. We will see.
The gears are tranny gears from a ratted out trx 250 utility 2x4 quad from the mid 80's. I had to do some machine work to them and it wasnt too fun even with carbide inserts, but i limped through it. I took the kick shaft out of the cr motor and attached the knuckle to the end of it and turned it down to fit the other gear over it. The shaft will ride on two koyo sealed bearings that will be attached to two pillow blocks that will be mounted to the frame. Hopefully i will have the pillows done today. A little welding and some set screws to hold the back gear to the shaft, and i also have to cut the splined end off of a 250r kick shaft and weld it to my new shaft that goes behind the motor and i should be done! Running this shaft means that i lost my original shock bottle mount, i had to put on a trx250r shock assy that has a longer hose and run it to the subframe like on the trx models. The shaft isnt any lower than the chain guard that originally went below the stock bottle mount, so no worries about the chain hitting it.
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