I recently replaced the layshaft bearing in the gearbox and at the same time replaced various bushes and also the kick-start return spring.
Since that time the kickstart does not return to the upright position after kicking the bike over.
Image 1 shows where it ends up and I have to manually return it to the upright position.
I have just taken it apart again to see if I can see why and can not find any reason other than the return spring is not tensioned enough.
When I rebuilt it, I was watching the Mick Hemmings video and noticed that the hole on the shaft in his video is at least 90° anti clock wise from the location of where my hole appears, which would give enough tension in the spring to make the kick shaft return to the upright position.
Image 2 shows the assembled items.
Image 4 is to show the position of the pawl before I put the case back on.
Image 6 is from the video where you can see the tang enters the shaft 180° from where the other end hooks over.
The only way I can see to sort this is to either get a new hole drilled or if its possible to shorten the spring and make a new tang.
Any advice much appreciated.
hello.cant help with the…
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The position in image 6 is…
The position in image 6 is correct. Looks like you have a pre-Commando kickstart shaft - which begs the question was it working before you took it apart?
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Kickstart return
Hi, me three on the kickstart shaft crack as well. I assume the kickstart shaft is installed and turned clockwise until it stops (where it would be at top of travel at rest) then spring is attached to shaft and pulled onto the inner cover? Good luck with it -Pat
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Possible crack, Ill…
Possible crack, Ill investigate.
Yes it was working before I took it all apart, annoyingly I did not keep the old spring to see if the previous owner had adapted it.
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Make sure the kickstart…
Make sure the kickstart shaft has plenty of end float.
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Ashley, how much end float…
Ashley, how much end float do you recommend.
And if it needs it, is this where it's to be fitted, "shims fit between the kickstart shaft and the inner face of the inner cover", as I've not had to shim anything before.
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Layshaft end float has been…
Layshaft end float has been quite well covered here: https://www.nortonownersclub.org/forum/excessive-gearbox-layshaft-endfloat . Layshaft and kickstart shaft float is the same thing.
If you have the standard ball bearing on the layshaft and the gearbox is otherwise standard, end float is unlikely to be of any concern to you. But just try shoving the kickstart shaft in and out when assembled to check that there is some; 1mm or more is good. Remember the spring will affect the movement you have.
Here's a picture of an original Commando kickstart shaft. Note position of spring locating hole relative to the pawl etc.
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Yes it is cracked, and the…
Yes it is cracked, and the hole is in a totally different area, so will be ordering a new shaft.
End float is at least 1mm.
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hello.
cant help with the spring . but, is that what seems like a crack in the kickstart shaft by the pawl or is it a trick of the light.
barry