Kick Start Return Not Returning on '66 T100

Big_Jim59

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Sep 13, 2010
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I posted this over at britbike.com and I will try here too because I am pretty stuck.

Because of the way the bike was abandoned, the water ingress was the most unkind to the kick start mechanism. The original spring was rusted through and the spring plate was corroded and pitted. To make matters worse I did not disassemble this gearbox. It came in a couple of boxes so I have no memory of how it actually goes together. I used to work on these 40 years ago but memories fade.

In order:
  1. I set the kick start return plate into the spring.
  2. I will give the spring one full revolution. I have found the a half revolution doesn't have enough return strength the lift the kick start lever and I can't get a third turn on the spring so two turns it is.
  3. I slide the outer gearbox cover on manipulating the shift lever slightly to get it into place and holding the kick start shaft with my finger.
  4. I hear nothing click or move. I tighten the out cover (with gasket).
  5. I try the kicker. It turns the engine and then just hangs there. It acts like I have only half a revolution on the spring. (I can't pull the cover back off without popping the spring off so I can't check this.)
  6. The kick start return plate may have slipped but I do not hear it doing so. I am including a picture of how I think the order of components should look. This is based on what I have and my understanding of the exploded view in the parts catalog. I have tried assembly without the spacers with no effect. I have had this cover on and off so many times I have lost count.

[Linked Image from i.imgur.com]


Oh. . . there is quite a bit of end play in the kicker shaft Maybe .010. The lay shaft thrust washer in in place and brand new. I can not sear to the condition of the pawl retaining disk (inside the second cover). I am sure it's in place but I could not swear to it's condition.

I really quite stuck. I would have the inner cover off if I thought it would do any good.
 
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