Kick Start Lever

Kick Start Lever. 1974 850 Roadster which I have owned since 1980. About 50 kicks after a complete engine rebuild, my kick start lever snapped at the end where it meets the mount to the kick start shaft. Looks like there may have been a preexisting crack, and I guess it finally gave way. Anyone ever have this happen ? Original kick start lever. Yeah, I know it's old, but they must have been making that stuff in China, way back then.

Question? is a pre MK 3..750 kick start lever any less beefier? than a Pre MK 3 850 kick start lever. I am aware that the MK3 is a slightly different design, but will fit with extra clearance for the exhaust etc.. My leg is still in half decent shape. Thanks!

The best thing I ever done was to replace my kicker with a RGM folding kicker ( T160 kicker with Norton sline) its longer and folds out of the way, makes it easier to kick as its longer with less effort.

Ashley

The RGM item sounds very interesting. I had a 750 kickstart lever on my 850 for a while, it was noticeably harder to kick – got around to replacing it recently with the later 850 lever, that turns out to be something like ¾" longer, enough to make kicking much easier. HTH

I fitted an RGM kicklever based on the T160 design, however in my case it was not any longer than the MK3 version it replaced so maybe there are different MK3 levers around. I bought my MK3 kickstart many years ago maybe in the 90's and it could be a pattern, the RGM tucks in a lot neater and will allow me to add on rearsets next year to help my hips.

Installed RGM's mk3 lever, provides a small advantage in leverage over stock... the folding version is hit or miss in terms of clearing rearsets (if you have them)

I am designing my own so will fabricate to suit, it does look like it gives a bit more clearance that the old lever, it certainly clears the exhaust pipe more.

Does the T160 style RGM lever give better exhaust clearance?

IBEX,
I would say it does though I haven't compared it. If you have standard pipes you'll have no problem.
What is does do is tuck in nicely as it swivels out of harms way . My old one was always rubbing on my heel. Plus if your old like me , it takes a bit of strain of your knees.

blacklav said:

IBEX,
I would say it does though I haven't compared it. If you have standard pipes you'll have no problem.
What is does do is tuck in nicely as it swivels out of harms way . My old one was always rubbing on my heel. Plus if your old like me , it takes a bit of strain of your knees.

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Have standard (balanced pipes) on my 1974 Mk2 850. Lever hits the pipe even though I have shimmed the right hand side pipe inwards, which makes them look rather odd from the rear.

The original lever on my '74 Mark II Roadster nicked the muffler. I replaced it with a '75 Mark III lever and it easily clears the muffler.

Thanks for the input gents. I just ordered the RGM folding Kick Start. FYI the vendor said it would clear RGM rear sets. I'm not running rear sets, so no concern to me. Anyway I'll let you know how it works.

NORTSTER1974 said:

Thanks for the input gents. I just ordered the RGM folding Kick Start. FYI the vendor said it would clear RGM rear sets. I'm not running rear sets, so no concern to me. Anyway I'll let you know how it works.

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Just an update. I received and installed the new RGM kick start lever. I had to wedge a large screw driver between the split in the collar to get it started, but once it started it went on nice. Drive the wedge/screwdriver in the split before you try mounting it, until you can gently tap it onto the shaft. I had to reset the screwdriver once or twice to get it on all the way. Seated perfectly. It has a nice bite on the front and rear splines of the kick start shaft. I don't foresee any problems with it flopping around like an old OEM lever or a junk EMGO. Happy so far.

The only thing is the rubber tends to walk off after a few kicks, as long as I can start it in two, I'll be good. Happy Motoring!

I've got the same lever on my 500 single (11.3:1 CR) so needs the extra length!
It's also good to clear the rear sets without requiring folding footrest
I did, however, give up on trying to keep rubbers on it - now just use it bare.
Cheers
Rob

NORTSTER1974 said:

The only thing is the rubber tends to walk off after a few kicks, as long as I can start it in two, I'll be good. Happy Motoring!

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I put a zip tie around the outside end of the rubber so it can't walk over the bump at the end.

I recently installed the RGM kick start lever. The extra length over stock helps to start the bike. Retracted, the lever stores out of the way better than the stock 750 or 850 styles.

Unfortunately, after using it for about three weeks, I noticed that the lever, when rotated out to the starting position, goes past 90 degrees, somewhere about 100 degrees. This means when you kick the lever, your foot tries to slide off. And it also means your foot tries to slide the rubber off the end of the lever. To RGM's credit, when I mentioned this, they said they have had this problem with a few levers, that the problem is with the part that bolts to the splined shaft, and they would send me a replacement casting at not cost. The problem could also be that the long lever is not machined correctly. I will update this thread when I install the new part.

The other niggle I have is there is no detent to hold the lever in the retracted position. Instead, the design relies on friction from the pivot bolt tightening the two parts together. Significant play has developed in the pivot after three weeks of use, and the lever now randomly rotates out when riding. I can see where this is going: if I frequently tighten up the bolt, I might manage to keep the lever retracted when I am riding. A better design would incorporate a detent.

Stephen Hill

robs ss said:

I've got the same lever on my 500 single (11.3:1 CR) so needs the extra length!
It's also good to clear the rear sets without requiring folding footrest
I did, however, give up on trying to keep rubbers on it - now just use it bare.
Cheers
Rob

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That's bloody gorgeous Rob !! (I'm referring to the whole bike not just the kickstart ) Did you build it yourself? if so did you document it here? What's the side panel made of Mahogany ?

Cheers,

cliffa

Stephen Hill said:

I recently installed the RGM kick start lever. The extra length over stock helps to start the bike. Retracted, the lever stores out of the way better than the stock 750 or 850 styles.
Stephen Hill

Click to expand...

Do you happen know the part number of the Kick starter??

Malc

050179
https://www.rgmnorton.co.uk/buy/kicksta ... 61d5f5fcfb

Yup, that is the kickstart lever I installed.
RGM has assembled a table that shows the length of the various levers: https://www.rgmnorton.co.uk/csi/1245184 ... onspdf.pdf
According to the table, the RGM product is longer than any stock Norton lever.

Stephen Hill

Regarding rubber walking off peg:

There was a thread on this.

kickstart-rubber-how-keep-from-kicking-off-t25186.html?hilit=Kick%20start%20rubber#p332664

Slick