Kickstart / rear brake question on MK3

I am now well under way in the restoration of my MK3, but have come across another hiccup in the proceedings.

I have installed a new kickstart (genuine MK3 from Mick Hemmings) amd a new stainless steel master cylinder for the rear brake, plus all new piston and pushrod etc.

The problem I'm having is that on full swing of the kickstart, the bolt head on the kickstart (that clamps it to the shaft) is kissing the bottom edge of the thin nut ( travel limiter) on the pushrod and in turn depressing the brake. Now I'm fairly confident that it wasn't designed to do this?

Therefore, as the cylinder mounting casting is in a fixed position on the footrest, I assume that this suggests that the large thin nut which limits travel may not have been adjusted correctly. I have fitted the kickstart with about 30 degrees of angle from vertical rearwards, and although I haven't tried it, I wouldn't have thought that placing this in a more upright position will help, unless there is a stop in the gearbox which limits travel?

Does anybody have any suggestions?

Also is there anyspecific information as to how to set the locknut on the pushrod? The only other option is to slightly reduce the bolt head size.

Reggie

The K/S bolt head should (just) miss the brake rod adjuster nut no matter how far the lever moves around (although there is a stop pawl in the gearbox that limits the lever travel).

With the brake in the fully off position the distance between the face of the large (11/16") nut on the brake rod should be 3/8" from the alloy master cylinder housing (the nut is there to act as a limiter so that the M/C piston cannot be pushed too far into the master cylinder.

Possibly the footrest assembly is set too low and may need to be repositioned upwards slightly? Or maybe it is bent?

Thanks for that. I assume that you mean the rear face (the round end) of the nut (which I have facing rearwards, with the nut side facing forwards) to alloy carrier, this gap should be 3/8 inch.

I've wound mine down to 2/8" (which is the end of the thread) and the head of the bolt still just catches the nut, and if I follow through, it then hits the bottom edge of the alloy carrier. I am now beggining to think that as you suggested the hanger could be bent, as there was a small corner chipped off this alloy (master cylinder) carrier, from the previous owner. I noticed this when I sent the alloy carrier away for painting. This suggests that it is not me that has re-assembled it incorrectly. I have also repositioned the kickstart, but this has not solved the problem.

Therefore I think it will be an attempt to bend the footrest hanger, or a new one.

Thanks
Reggie

Reggie said:

I assume that you mean the rear face (the round end) of the nut (which I have facing rearwards, with the nut side facing forwards) to alloy carrier, this gap should be 3/8 inch.

Click to expand...

Yes.

Actually I checked the Lockheed service notes and the EXACT spacing distance is a tiny bit under 3/8". The notes give the distance as 0.35-0.37" (8.9-9.4mm) 3/8" being 0.375" (9.525mm)

Thanks. Reggie