Kick start stuck

ZOOMER52 · Jul 17, 2016

I need some help with this one. I have a 75 850 Commando. The other day I tried kick starting it and the kick start lever went down and came back up only 1/4 way from the bottom of its swing and it jammed there, wont go up and wont go down. If I pull in the clutch I can move the lever from the stuck position, about 7:00, up to the 2:00 position. And then it'll go back to the stuck 7:00 spot. I removed the outer and inner gearbox covers and found the lay shaft first gear bushing had been chewed up by the pawl so I replaced the bushing put it all back together kicked it and got the same result, stuck at 7;00. since then I have replaced every bearing and bushing in the gearbox, checked end play on the starter shaft and shimmed out the slop till I have .0010 end play. kicked it, stuck at 7:00. I need to resolve this before summer slips away.

auldblue · Jul 17, 2016

I haven't got a 75 but I can't work out how the Paul has chewed up that bush and when you take your weight off the kickstart it's the spring that pulls it back to the stop. If it was me I would think the problem was in the assembly but I could hazard a guess les might have the answer.

Jimmy

The kick start can creep back with a dodgy lay shaft bearing ,but you say it has been changed. I have never had it happen so can't comment from experience.

concours · Jul 17, 2016

ZOOMER52 said:
I need some help with this one. I have a 75 850 Commando. The other day I tried kick starting it and the kick start lever went down and came back up only 1/4 way from the bottom of its swing and it jammed there, wont go up and wont go down. If I pull in the clutch I can move the lever from the stuck position, about 7:00, up to the 2:00 position. And then it'll go back to the stuck 7:00 spot. I removed the outer and inner gearbox covers and found the lay shaft first gear bushing had been chewed up by the pawl so I replaced the bushing put it all back together kicked it and got the same result, stuck at 7;00. since then I have replaced every bearing and bushing in the gearbox, checked end play on the starter shaft and shimmed out the slop till I have .0010 end play. kicked it, stuck at 7:00. I need to resolve this before summer slips away.

Assumed that, because you shimmed the kicker shaft, you retrofitted a roller layshaft bearing, correct? Did you enlarge the I.D. of those shims to clear the radius on the kicker? Is the pawl retraction and stopper lug still in good shape? You tested it as you assembled? Did you mean to write .010" end play?
Also, has this trans been working well for a good long time? Or rebuilt/repaired in the recent past?

Welcome to the forum :mrgreen:

Kick start stuck

ZOOMER52

auldblue

concours

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