BRONZE BUSHINGS INSTALL
BRONZE BUSHING INSTALLATION GUIDE
For KTM / Husqvarna / GasGas 2-stroke electric-start models
🧰 Tools You Need
- 8mm, 10mm sockets
- T30 Torx (if your cover uses Torx)
- Small punch / drift
- Hammer or small mallet
- Brake cleaner or degreaser
- Light grease
- Bronze bushing kit
- Loctite 638 or similar retaining compound.
🔧 STEP-BY-STEP
1. Remove the starter cover
Take off the small right-side starter/ignition cover (3–4 bolts depending on model).
This exposes the starter gear/bendix area.
2. Pull out the starter shaft + bendix
Grab the starter shaft and gently pull it outward.
It will slide out with the bendix gear still on it.
Set the shaft aside.
3. Remove the old bushings
Look into the engine-side cover you removed — you'll see the old bushing(s) pressed in.
Use a small pry tool to remove standard bushings.
Repeat for all bushings.
4. Clean everything
Clean the bushing holes (housings) with brake cleaner.
Clean the shaft so there’s no dirt or metal.
5. Install the new bronze bushings
Apply retaining compound (e.g. Loctite 638/648), apply a very light bead around the outer surface of each bushing before installation.
Line up the new bronze bushing with the hole.
Tap it in with a punch until fully seated and straight.
Install all bushings the same way.
Apply a tiny bit of grease inside the bushing.
6. Reinstall the starter shaft + bendix
Slide the starter shaft and bendix back into the motor.
It should slide smoothly through the new bushings.
Make sure the gear meshes normally.
7. Refit the cover
Reinstall the starter/ignition cover.
Tighten the bolts evenly.
Wait 24 hours for retaining compound to fully cure.
8. Test the starter
Hit the start button.
It should sound smoother and crank easier.
If something feels rough or abnormal — stop, disassemble, and re-inspect shaft, bushing alignment, and gear fitment.
If the shaft doesn’t slide smoothly, the bushings may be slightly misaligned → tap them a tiny bit to straighten.