Cheetahchrome pull start kit for stock points ignition

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Quite a few people have written to me requesting if I could build them a pull start unit for their stock Peugeot 103
bikes. Most want these just for the clean look added to their build, but all are very pleased with the new takeoff
performance feel that has been added by removing their pedal starting clutches. Some even add the kit and never do
take out their starter shoes. They just want the look and novelty of pull staring the bike but still being able to pedal start
as well.

This tutorial will help you install the pull start kit. The process is nearly the same as installing the Lepartie CDI pull start kit
but has an additional mod that must be done to the flywheel rivets using a grinder. I have even hijacked some of the pictures and text from the Lepartie pull start tutorial.

As with the other Peugeot pull start you will still need a thread tap and drill bit to install a threaded hole in your cases
motor mount. You will only need basic hand tools and a power drill for this install. You will also be required to make a trip
to your local auto parts store to buy a M6x1.00 thread tap and the corresponding drill bit 13/64. These two tools together
will be about 12.00.

thread tap


This bike will be the victim of todays molestations.

bike


This is the contents of the boxed kit. For some reason I forgot to include the three allen bolts and nylock nuts.

goodies


Before I remove my flywheel and stator I will at this time do the flywheel mod which is just basically grinding off a bit of
of the rivet heads so that the shoulder of the starting pawl can sit flush onto the face of the flywheel.

grind rivets

Just get them kinda flat like these.

flat rivets

Using a less aggressive grinding wheel like this flapper wheel is my favorite.

flaper wheel


With the grinding done you can remove your flywheel and stator plate. I have actually just left the ignition in place
and used my fingers and pliers to remove the case nut. I removed the stator plate for the pictorials sake.
I recommend leaving your pipe in place so that you are sure you don't position the lower bracket so that it hits the pipe.

I now remove the one nut from the pictured case bolts. You may turn out to be unlucky and you will find that your
bolts run the other direction. In that case you will have to remove your clutch and variator and flip the bolts around so
that the threads are pointing towards you. Boo Hoo for that.
You will want to remove your clutch anyhow to shake out those heavy ass starter shoes that keep you from getting off
the line and going straight to heaven.

remove nuts


Next position the lower aluminum threaded bracket so that you can start the bolt and then thread it all the way in. Don't
get the bolt and bracket wrench tight yet.

lower bracket


Now you can re install your stator plate and set your timing set with your magic tools or using the poor mans method

stator on


The starting pawl has a shouldered step cut in it to make room for the flywheel rivets.

pawl


The provided flywheel nut and washer a unique to this kit.

nuts on


Bring over the pull start body and with the weld seam pointing down, press the body onto the sealing rim of the stator
plate. It will stay in place as it was built to fit perfect. Then you can align the hole of the body mounting tab with the
lower aluminum bracket. Thread the lower bolt and spacer in place.

mock up

I continue to develop and improve these kits and found that when using the kit with the stock points stator, the large diameter of the kit demands that you need to create your top threaded mount hole to the right of the spark plug wire hole and as close to the right hand edge of the swinging motor mount as you can. If you put your mount to the left of the plug wire hole It could make contact with the swing arm and hinder full variation.
Below are some new pics I have added to help illustrate the proper position of the top mount hole for the stock stator plate application. Remember, I hijacked some pics from the La Partie install thread. The La Partie pull start is much smaller than the stock kit.

Your lower mounting block should still be just finger tight so you should be able to rotate the pull body to the right so you can Eyeball your new hole as close to the edge as feasible.

rotate right

marking for mount hole


At this time, with the body mock fitted, you can tighten the case bolt for keeps

wrench tight


Now lets move to the top where we will create a threaded hole in the motor mount to accept the top bolt and spacer. Use
a small phillips screwdriver or anything strait and pointed and while looking straight through the top mounting tab, hammer
a nice dimple in the motor mount, This is where we will drill and tap.

dimple mark


Remove the housing and use your drill and 13/46 bit to drill through the dimple. Cover the flywheel with a rag to catch
the drill cuttings

drill drill drill


This last step can be kind of intimidating and it is the tapping threads into the hole you drilled. I was lucky to have a "T"
handle to support my tapping tool but I have done this using a small set of vice grips to grip the tap.

"T" handle


No matter what you use it is just important that you keep the tap cutting straight and square with the world.
Just go slow and keep looking at different angles so that you can correct the tap if it gets too wonky to one side.

keeping straight


Mock fit the top mounting bolt and spacer.

top bolt


Last you can mock up your kit and put in both bolts and spacers and try the pull. WOW!! this thing looks really great
and with no starter shoes in the clutch the bike just rips off the line straight up to the power band of the pipe.
The little rope spooling component included in this kit seems pretty robust but I recommend that you not pull
the rope all the way to the end of the spool as the spool is plastic and if you live in cold climate I imagine it might
snap the rope or the plastic spool. I have found that short quick snapping jerks work best and really get the motor
Spinning for a smooth start. If your rope should break, here is a link to easily repairing the spooling unit. [rope broke]

done


Wow this thing really looks and works great. This bike has shortie pedals so they clear nicely. The side cover fits as
always and doesn't touch the pull start.

looks great


Here is the kit installed on a custom bike. People just love the looks of these even on just everyday stockers.

Peugavo


I am now finished with this Wiki page. If you have any questions about the tips I suggested, or are having trouble with the process or can suggest how I can correct a mistake or to make the page better, contact Cheetahchrome