Airone kickstart shft removal

[jerry atric]

A A friend of mine is stripping an Airone engine but the gear shown will not come off. At first sight, you would expect it to unscrew but there is a woodruff key in there. He's tried heat and a 10 ton press but  it won't budge. Has anyone done this before and how did you get it off please? Thanks

[Patrick Hughes]

I had the same problem on my Falcone, I made a large socket castellated to fit the slots in the nut and used a n impact driver, it came off straight away. I can't remember if it was LH or RH thread. The parts behind came off easily

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From: guzzi-...@googlegroups.com <guzzi-...@googlegroups.com> on behalf of jerry atric <baconsl...@gmail.com>
Sent: Thursday, 30 July 2026 12:51:36
To: Guzzi Singles <guzzi-...@googlegroups.com>
Subject: [guzzi-singles] Airone kickstart shft removal

 

A A friend of mine is stripping an Airone engine but the gear shown will not come off. At first sight, you would expect it to unscrew but there is a woodruff key in there. He's tried heat and a 10 ton press but  it won't budge. Has anyone done this before and how did you get it off please? Thanks

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[Claude Hicter]

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Hello everyone 

Looking at the workshop manual, I think it’s a right-hand thread.

Judging by the position of the spanner.

If that helps. 

Claude. 

[Patrick Hughes]

Tried that foe ages, would not budge.

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From: guzzi-...@googlegroups.com <guzzi-...@googlegroups.com> on behalf of Claude Hicter <hicter...@scarlet.be>
Sent: Thursday, 30 July 2026 14:21:43
To: guzzi-...@googlegroups.com <guzzi-...@googlegroups.com>
Subject: Re: [guzzi-singles] Airone kickstart shft removal

 

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[jerry atric]

But if you look at the top photo, there's a key in there. Or is it something else?

[Claude Hicter]

The manual states that you must hold the shaft firmly with a socket spanner.

I think that’s the spanner you can see in the photo. 

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[guzz...@aol.com]

when I have encountered such problems while using heat I also spray penetrating oil on the part hoping it will soak in faster and then patiently keep trying.

Tim

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[guzz...@aol.com]

Is there a hidden grub screw behind the gear??

Tim

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[Patrick Hayes]

On 7/30/26 04:51, jerry atric wrote:
> A friend of mine is stripping an Airone engine

I inadvertently sent this reply just to Jerry Atric. Now sending a
duplicate to the forum.
-----------------------------------

First, it is standard threading. Righty-tighty, lefty-loosey. Yes,
shock not force does the trick. Air gun involved. But you also need to
jam something into the drive pinion or kickstarter to lock the shaft
from spinning while you hit it with the gun.

Second, there is no provision for a woodruff key in that position. There
is, however, an important reason why that part has a keyway slot in it.
The very outer tip of the output shaft has ONE TOOTH sticking up from
its perimeter circumference. The castelated part you are trying to
remove will unscrew fully and then it has to slide over the exposed one
tooth on the shaft tip. Unfortunately, I don't see any such tooth on
your shaft. Oops. Bad juju. Did someone grind that away? That tooth
also locks the 'manicotto' or left-threaded hollow tube which locks the
clutch spring adjuster. Absent that tooth, the clutch can go all out of
adjustment quickly and lock the transmission. We need to hear and see
more about said tooth. I just went through the Airone manual and that
tooth should be pretty obvious. See the attached images. I have seen a
replacement welded on and ground back to proper size. It is not a
critical dimension, but it is critical to have.

Third, there is a locking grub screw involved but that is deeper in
under the kickstart mechanism and locks the chain drive pinion. Not an
issue yet for this disassembly. See pic.


--
Patrick Hayes
Fremont CA
Falcone-NT and SuperAlce
www.motohayes.com

[RICHARD YAMANE]

Patrick, you are a Godsend!
I was thinking it should be right hand thread just from the ramping on the ratcheting. The keyway was a mystery.

Rick Yamane
Importer of Vape/Powerdynamo ignition systems and Polisher of bikes at Motion Pro

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[jerry atric]

I second that, Rick. Whenever I post a question on here, I always think, once Patrick sees this, I'll be OK. That's not to denigrate anyone else's answers, there's so much helpful knowledge on here and a lot of good folk. The group has eased my bacon slicer journey no end. Long  may it continue👍🏻