Kickstart for the Hima

[sam2019]

Minutes before I had to leave for the airport to fly to Kathmandu I received an email from a guy I had been in contact with a while ago regarding the kickstart and the 6th gear ideas.
I replied he should join here which I hope he eventually will. In the meantime here is what I got so far:

I've been working on the kickstarter for the himalayan and i might as well give you an update.

I made a drawing for the setup:
https://geargenerator.com/#900,350,...87234042553191,4.7,27,-105,0,0,0,0,0,1,3,1904

And then made some prototypes with 3D printing.
I think it's definitely a proof of concept.
Next will be investigating dimensions for the kickstartershaft and kickstarter itself.

Any news around the 6-speed conversion? I looked at it for a bit, It really seems like it was designed for a 6-speed, so it should be possible.

thanks

 

[Sullivanpbr]

The kickstart is very interesting. It seems like something that should definitely be possible from an engineering standpoint .

I feel like kickstarters should be standard equipment on a bike like ours. I have never understood why kickstarters went away, well I guess I do (cost savings.) Last year I found myself stranded while riding in the cold weather. My bike had sat out in the below freezing temperatures and it had killed the battery. If I had a kickstarter it would have been nothing more than a minor inconvenience.

 

[sam2019]

There is actually a program online that help making gears, this is from the guy who sent me the Hima designs:

Involute spur gear generator and simulator

Gear Generator is a tool for creating involute spur gears and download them in SVG format. In addition it let you compose full gear layouts with connetcted gears to design multiple gears system with control of the input/output ratio and rotation speed. Gears can be animated with various speed to...

geargenerator.com

 

[Dool]

We will likely need a program that works out the position of the Shaft exit through the Case.

 

[sam2019]

He just answered (I keep his name private as long as he does not decide to show up here by himself). There are other mechanisms involved, not just a few sprockets and a shaft. The cover wall seems not only thick enough - it has all the props for a shaft to go thru - almost as if in the last moment it was decided to leave the kick out of the design but most elements where already in place.

The shafts RE offers for the Bullet (old and new type) and the 535 Conti are in the 10-20 US$ range as I suspected.

Also: Amazon offers a surprising selection of "assemblies" although most are for scooters or small bikes.

Amazon.in : Kick Start Shaft Assembly

 

[sam2019]

also a wide range of 3rd party stuff

ALLEXTREME TBKL-002 Kick Lever for Bullet Classic Electra and Standard 350cc and 500cc Kickstart Lever Price in India - Buy ALLEXTREME TBKL-002 Kick Lever for Bullet Classic Electra and Standard 350cc and 500cc Kickstart Lever online at Flipkart.com

Buy ALLEXTREME TBKL-002 Kick Lever for Bullet Classic Electra and Standard 350cc and 500cc Kickstart Lever for Rs.549 online. ALLEXTREME TBKL-002 Kick Lever for Bullet Classic Electra and Standard 350cc and 500cc Kickstart Lever at best prices with FREE shipping & cash on delivery. Only Genuine...

www.flipkart.com

 

[sam2019]

we would also need something like this

Ubersweet® Imported Kick Start Starter Lever Shaft Assembly : Amazon.in: Car & Motorbike

Ubersweet® Imported Kick Start Starter Lever Shaft Assembly : Amazon.in: Car & Motorbike

www.amazon.in

 

[sam2019]

and it rolls ...

 

[sam2019]

looks solid to me ...

 

[Dool]

and it rolls ...

The Orange gear would represent the one which is normally mounted to the Clutch Basket, is it there on a Himalayan? I dont remember looking for it when I did the Plates.
Downside of all this will be a couple of extra gears turning when its running, noise etc.

 

[sam2019]

Downside of all this will be a couple of extra gears turning when its running, noise etc.

the downside I would consider is that if either part of the additional sprockets fails it tears down half the engine with it so this has to be 100% which is hard to do given the financial means we have vis a vis the projected numbers that could be sold. I am not even talking profit, I am talking less loss than with the 477 project

 

[sam2019]

But then again - no risk no fun, and we all have to die one day, and the last shirt has no pockets, so lets spent it all now ...
add your own meme as you see fit

 

[sam2019]

Getting the right side of the engine cover and an assortment of kickstart handles from 350 bullet, pre-unit bullet and 535 conti plus one bullet kicker internal mechanism to the guy. I hope he can use the stuff to find out how it will work to kick the Hima

yes, thats my "new" BS3 that is cannibalized for the good cause!

 

[barima]

Hi everyone,
Glad to hear you guys are also enthusiast about getting a kickstarter on the himalayan. Really looking forward to receiving the parts, this will definately speed up the process.
Cheers, Barry

 

[barima]

The Orange gear would represent the one which is normally mounted to the Clutch Basket, is it there on a Himalayan? I dont remember looking for it when I did the Plates.
Downside of all this will be a couple of extra gears turning when its running, noise etc.

Yes, the orange gear is already on the clutch basket. It confirms my thoughts that it was all pre-designed by RE. Luckily one less sprocket to make i guess.

 

[thony]

OK this is cool. Sign me in as usual.

 

[sam2019]

Got an email asking when the kick will be available. I love those optimists. Dunno why they don't write to the forum but it seems "forum shyness" is quite wide spread. In any case: I 'll answer it as best I can:

In my estimates it will take 4 weeks to reach for the parcel from India to the Netherlands. Then assuming barima is very motivated it will take at least another month to establish a working model - that will depend heavily on the availability of a pre-fabricated mechanism (the stuff that makes the kicker come back and disengage after the engine starts running). Then we have to find sources for the material we need to manufacture (at the very minimum 2 sprockets) which will take a minimum of 6 weeks from sending in prototypes or plans to production. Add to that various shipping delays, some national, some international and you can add 2 more months.

So here we are with about half a year - and that is the optimistic calculation. If we then install it on at least 2 of our own bikes and use those with kick starting every time to evaluate the solidity of the construct - that may take another 3 month or so.

 

[Dool]

Wanting a Definite answer to a question just invented

emails should be taxed.

 

[barima]

I have a xr250r from a friend around in my workspace for repairs and "borrowed" it to make some pics, because it is actually quite close to what we are aiming for. While doing this i discovered two more bumps in the road for this development:
- Having a Givi engine guard blocks the route of the kickstarter turn out.
- the brake pedal should be relocated to the backside of the frame (most off-road bikes i know have this, why RE put it on the outside is beyond my comprehension...). This shouldn't be that difficult but the brake pedal needs some modification.

 

[Dool]

Lever is a Good fit shape wise , the Mechanism in the Pillion pegs could provide your answer in a Fold Up Peg.

Get leg Guards from Sam and ditch the Givi's