Mk3 Kicker Issue

Helping a friend with a MK3 which had kicker that was not engaging with first lay gear to turn engine over.
Found the pawl badly worn so fitted new pawl with new pin and a new pawl spring, new clutch lifter sleeve, lifter lever, lifter roller and pin.
There was a shim present btwn kick shaft and inner cover, so presumably a roller layshaft bearing has been fitted by previous work. Trusted all would be good. Kicker now engages first lay gear and engine can be started on kick. But immediately we heard/saw the kicker arm not fully up/home with engine running and could feel ratcheting vibration on the kicker arm.
Here is a video showing non running checks of kicker moving when pushing bike in gear back and forth.


What is the issue, incorrect endfloat?

Too little endfloat would be the obvious one but I would not jump at reshiming, my first port of call is the new pawl is too wide, misplaced or engaging and rubbing on the teeth inside first gear as its not sitting against the kickstart stop plate properly.

See part 33

kommando said:

Too little endfloat would be the obvious one but I would not jump at reshiming, my first port of call is the new pawl is too wide, misplaced or engaging and rubbing on the teeth inside first gear as its not sitting against the kickstart stop plate properly.

See part 33

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I could not see/feel any endfloat on layshaft but we did not have a dial indicator at the time to confirm. I do have one but did not bring it to friends place for our work.

Another point, the kicker arm was hitting the brake/foot rest mount when trying to reach fully up/home position. We removed the kicker, rotated it back a few spline teeth and seemed to prevent this interference...but later saw it in contact again and had to move it some more teeth back. The kicker is now maybe 10 o'clock position when at rest, not 12 o'clock. Is that ok? No change in the actual engagement problem.

If the kicker is not coming to rest at the same point then something is up and there is enough binding going on to overcome the kickstart spring. Its got to come apart, its F'd and there is no point of more speculation, only a proper internal inspection will reveal the fault/faults. There is too little endfloat but I get the impression its not the shim that's the issue but either new parts or the assembly is not right.

Tornado said:

I could not see/feel any endfloat on layshaft but we did not have a dial indicator at the time to confirm.

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You can measure the gap (with stacked feeler gauges etc.) here with the shaft pressed in and pulled out.

Can you guys contact the previous owner to ask if the layshaft bearing was ever changed out ? Beats presuming after finding a shim in there , to ascertain . On my MK111 , the pawl had worn out first gear inner teeth as well , so both 1 st. gears were replaced .

Torontonian said:

Can you guys contact the previous owner to ask if the layshaft bearing was ever changed out ? Beats presuming after finding a shim in there , to ascertain . On my MK111 , the pawl had worn out first gear inner teeth as well , so both 1 st. gears were replaced .

Click to expand...

Do not think previous owner knows. The bike has had much work done by local Norton specialist, Dave Sandquivst, RIP, so he most likely worked on the gb and should be right. But of course checking what bearing fitted is wisest. Was trying not to disturb that which was in good working order...

Tornado said:

Do not think previous owner knows. The bike has had much work done by local Norton specialist, Dave Sandquivst, RIP, so he most likely worked on the gb and should be right. But of course checking what bearing fitted is wisest. Was trying not to disturb that which was in good working order...

Click to expand...

O.K. we know it's a lot of work , but inner and outer should come off again to explore .