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post #1 of 8 (permalink) Old 10-21-2009, 12:48 PM Thread Starter
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kickstart ?

hey guys how is everybody ? so my kick start arm sits at about 9 oclock and i would rather it be at about 11 oclock where it should be. so i pulled the ks cover off and tried to remove the ks arm but the bolt going through the ks holding it to the shaft is seized.i mangled the bolt trying to remove it.how is that bolt/pin removed ?.2nd, how do i remove the kickstart quadrant off the shaft ?. thanx guys.
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post #2 of 8 (permalink) Old 10-21-2009, 01:16 PM
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The kickstart cotter pin should normally just knock out, the way to do it without damaging the threads is to screw an old nut onto it. If it is too mangled, start by cutting off the damaged part to give you a flat(ish) surface to get a drift onto, and then get yourself a LARGE hammer, sometimes a little WD40 or some heat also helps.

Once you've got the kickstaft off, you might find that the shaft has burred over, if it has you will not be able to withdraw the shaft from the gearbox outer cover. I've found the best way to fix this is to grind off the burrs with a dremmel.

As for removing the kickstart shaft from the quadrant, I'm not sure, but you may find it is not necessary, you might just need to put a little more tension on the return spring or maybe a new spring.

I hope this helps

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post #3 of 8 (permalink) Old 10-21-2009, 01:36 PM
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My guess is that the kickstart gear has been installed on the shaft in the wrong orientation (unless your spring is so weak that it's not returning the lever to the stop).

That's going to require a hydraulic press to remove & re-install after correctly re-aligning the teeth.

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post #4 of 8 (permalink) Old 10-21-2009, 02:01 PM Thread Starter
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My guess is that the kickstart gear has been installed on the shaft in the wrong orientation (unless your spring is so weak that it's not returning the lever to the stop).

it was installed 1 tooth anticlockwise. i got it all apart and relocated it to the right spot. the cotter pin was way to F'ed so i put a bolt through.
i do need a new kickstart spring now. when i put it back togeather how much should i preload the spring ? some say 1 rotation anti clockwise some threads say 1.75.
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post #5 of 8 (permalink) Old 10-21-2009, 04:29 PM
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Just preload it to where it gives a good strong return; I've never counted the number of turns.

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post #6 of 8 (permalink) Old 10-22-2009, 11:11 AM Thread Starter
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so i put the new spring in the kickstart and put every thing back together and it started 1st go but after i stoped the motor i tryed to restart it again and now it feels like it has a 1/4 of the compression *** ?
could it be a stuck valve or some other thing with the kickstart that im not aware of ?
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post #7 of 8 (permalink) Old 10-22-2009, 12:32 PM
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post #8 of 8 (permalink) Old 10-22-2009, 11:05 PM Thread Starter
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Big Thanx.

i just want to take a moment to thank you guys aswell as plewsy and ozbloke and everybody who helped me get my bike running like a champ.im still very new at being a triumph mechanic and not 1 of you guys shot me down for asking stupid questions,as a result i have learnt a hell of a lot and hope to keep learning (with your help of course )
i would love to buy everyone a beer but a pic of my bike might be all i can do.
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