I recently fitted a new kick start shaft, now when I kick it over the back wheel rotates and the kickstart won't return properly. I've had it all apart again and checked that everything is ok ( which it appears to be) but on reassembly it's exactly the same.
I have run it up on the stand and set it to a very fast 'idle' selected top gear and run it for about 5 minutes and it seems fine in as much as the kickstart doesn't try to move.
Any ideas please?
Dominator kickstart
- Log in to post comments
Dominator AMC Gearbox Fitting New Kickstart Shaft
Hi Peter.
Found my notes: with (genuine Norton) new gaskets the minimum end float for kickstart shaft is
.010" (10 thou) and max' .020".
Shim(s) I used are from early Commando Isolastics:
060775 = .005", 060776 = .010", 060777 = .020", 060778 = .030" (unlikely).
You may have to reduce the OD of the shim so it fits snugly at the end of the kickstart shaft inside the "stops" on the inner cover.
I set the magnetic base on the DTI (Dial Test Indicator) on the hydraulic ramp to get the measurements.
Method: without a gasket fitted to the inner cover, shim kickstart shaft until resistance is felt. Dismantle and fit a new gasket. You should find the new gasket has provided the required clearance. If not, start again.
Keep a stock of new gaskets!
- Log in to post comments
Thanks for the replies, the…
Thanks for the replies Tim, the odd thing is, and therefore I believe the cause of the problem, that I have no endfloat at all on the kickstart shaft(?). I now have the kickstart returning ok but the sprocket is still turning and feels a bit tight, and that's without the outer cover being in place.
- Log in to post comments
Fixed
Tim, I've found the issue and fixed it ! The steel kickstart top hat bush in the inner cover was not fully home ( not something I had touched), I warmed the casting and seated it down and all was ok , end float on the k/s shaft and everything working as it should. Took it apart again removed the bush cleaned everything and put it back with a dab of loctite. Shimmed it up and now ready to fit.
- Log in to post comments
Hi Peter.
First thing to think about is are all the parts used genuine Norton, including the gaskets, which act as spacing shims. The end-float on the kick-start shaft has to be accurately measured. Too little clearance and the gearbox may lock up. After removing the kick-start spring, I had to ream the inside bush and the kick-start bush in the outer cover because the tiniest amount of swarf stopped the kick-start shaft returning to 12 o clock.
Hope that helps