So I bought shortman's 300 bottom end for the kicker and some spare parts like the right side cover and water pump. And maybe the left cover if the stator goes into it, so I can rip off the starter...
Today I finally got around to tearing into it. Got the kicker parts off pretty easily.

So now comes the hard part of putting it on my bike.

The question I have is, how do I clean the gaskets for reassembly without screwing them up? I was planning on getting spares, but after taking apart an old motor and removing the gaskets intact but dirty I got to wondering...
Only thing I know I definitely need is a new seal for the kicker shaft.

As an unrelated question, how do I tell if the clutch plates from the 300 are good. I'm guessing they look better than mine with 25,000 miles on them(but haven't seen them). Do I measure the thickness?

 

I've gotten lucky re using old gaskets by cleaning surfaces with a non film cleaner(laquer thinner, brake cleaner) and using rtv silicone.
good luck
marc

 

Ive never cleaned any old gaskets, i just retorque to proper value and it doesnt leak

 

You'll need the foot peg mount from a 07 and earlier bike. The kick lever will hit yours before full kick/stroke.

 

Thanks zomby woof, been looking on e-bay for one, might try and see if my 650 peg will work (since I haven't had the time or energy to get into that bike), it already donated a clutch cable to the 250 as an emergency swap.

 

And that goofy wide footpeg mount will easily bend when you wack it with a rock on the trail. I'm on my third. It really hangs out there.