Hello Folks.
I have a problem with the kick start lever and shaft on my 1969 Commando Fastback which, despite regularly checking the torque at 25ft lbs., have both stripped, a problem which has afflicted Nortons for as far as I can remember which is 1962 when I bought an ES2.
It looks to me like a new kick start lever and shaft are needed but I’m not sure if this can be undertaken with the gearbox still in the frame.
I’m a pretty competent mechanic but gearboxes scare me so I was wondering if there was another way which would ensure the same problem did not happen again.
What sprang to mind was to cut a keyway (Woodruff type) in the kick start shaft and the kick start lever which would be held tightly in place by the pinch bolt with no strain at all on the pinch bolt and no fear of the kick start lever spinning on the shaft.
Has anybody tried this or is it not possible?
Thanks in advance, Gents.
You might get away with…
You might get away with drilling down a spline (say 3mm) and fitting a short 3mm pin . Tighten the lever clamp bolt up till there is no discernible play between the lever and the shaft, Using the proper bolt this will most likely be quite a bit more than 25ft lbs. In other words don't use a torque wrench on this! If that fails a new shaft and lever needed but again tighten till no play evident.
The amount of Nortons that have the kickstart loose on the splines has to be seen to be believed. I used this as one of the dismissals in judging the best bike category at the national rally.
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Our Atlas is wearing the…
Our Atlas is wearing the 1960 Kickstart off my 99 , its the only one that would stay the course. Has to be kept tight with a high tensile bolt . Think the metal was better stuff back then.
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Yes
You can replace the kickstart shaft with the gearbox in the frame. Be aware that there are pattern parts available for both the shaft and particularly the kickstart that are very poor quality. You need to avoid these. Andover Norton would be your safest place to buy them. As others say, ignore the 25ft lbs for the kickstart. That bolt needs to be tight.
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Many thanks for your advice,…
Many thanks for your advice, Gents.
I'm going to try the drill/pin method which, should it not succeed, won't make any difference as the shaft is naff anyway.
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... had a round pin in a drilling between the shaft and kickstart, It worked well so I never bothered to change it. I suspect the shaft is hardened so may not be easy to drill.