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Discussion Starter #1
Hi guys,

I tried to put the outer gearbox cover back on my machine today.

First attempt, kickstart lever would no return to upright position.

Tightened the spring a bit and tried again. Worked OK until I tightened up the cover.

Tightened a little more and spring broke.

While a wait for as replacement part - any tips on fitting procedure.


On another point, I suspect the seals for the Oil Pressure Release Valve Body are perished. Got the cap off no problem, but how the heck do you get the body out??? I can't get 1" A/F socket at it, 'cos it's sunk into the crank case.
 

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The orietation of the quadrant, shaft and spring should look like this:


The kickstart pedal needs to be wound anti-clockwise against the spring for about a turn to clear the stop and give it some tension before attempting to fit the outer case.
 

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Discussion Starter #4
Cracked the kickstart problem!

I assembled everything without the kickstart spring.

The kickstart spindle became very tight when I nipped up the cover.

When I assembled the new kickstart quadrant and spindle, I hadn't hammered the quadrant far enough down the shaft, so it was fouling on the inner gearbox cover ever so slighlty.

A few more taps with Irish spanner and turns easily by hand, so should be fine when I get the new spring.


Still stumped with the removal of the Oil Pressure Release Valve body.
 

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WRT the oil pressure release valve...if its working I`d leave it alone.
It would appear that its been overtightened (and thread damaged).
There should be a fibre washer between the housing and the case, I suspect its missing.
Picture?

Anyway all the inner stuff is available after removing the dome nut.
Measure the spring length (1 3/8").
Also the piston diameter .5605/.5610"
The open end of the piston faces the spring.

The only trouble may be the oilway, which could be out of alignment with the feed.
 

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Discussion Starter #7
Hi Caulky,

There is a fibre washer between the housing and the case, but if it's anything like the seal between the dome cover and valve body, it is perished.

Because the valve body is recessed into the case, I can't enough purchase with a spanner or a socket.
 

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The only reason to remove the whole body is to renew the fibre washer if its leaking or to clean the gauze filter.
This doesn`t need to be very tight...fibre washers break easily.
I suppose at a pinch its possible to undo it with a hammer and punch :eek:
Gently!
 

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Discussion Starter #10
You the MAN Caulky!

A few taps with a punch was enough to get it slackened.

The PO had tried the same stunt, but had managed to chew up the face which mates with the case, so the washer was badly distorted.

Filter, piston and spring all look fine.

One more little job done, God knows how many more to go. :)
 

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Thanks guys!!
Yet ANOTHER useful (today in fact) bit of information shared by the posters here has saved me (again).:)
 
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