kickstart sticking

[Jules]

"It returns fine with the nuts done up hand tight but as soon as I put 10ft/lb on the nuts it sticks at the bottom inch of throw".......doesn't this suggest that the case is distorting/twisting somehow Musky and nipping up on one of the bushes?? can you assemble without the gasket fitted at all perhaps as a test, or does that then pinch something somewhere? or maybe assemble with some thin shim material between the cases where the bolts are for a test??
another thought from left field, maybe one of the bushes/shaft is a bit dry at one point (there's probably a bit of ovality in the shaft and bushes and where the 2 "peaks" meet...maybe a bit of blue to test?)....

[muskrat]

G'day Jules.
Yes I thought of the cover being distorted, but why all of a sudden. The cover hadn't been touched in years.
I tried with no gasket and the shaft binds with no endfloat. Good idea about fitting shim over the studs to test. I did "blue" the shaft and saw a high spot that I removed and then polished but it didn't help 
Looks like rain for the next few days so it's more time in the shed.
Cheers 

[muskrat]

G'day Jules.
 I did the blue of the outer bush to find the rub marks. I very carefully polished them out (maybe 1/4 thou) still binding. Now I use 0.8mm gasket material so cut some 0.4mm paper in the form of washers and put them over the studs. Tightened the three screws first then put 10ft/lb on the nuts. Hooray no binding. So as a stop gap I'll use extra sealant on that set up till I make new dowels and flatten the cover.
Cheers

[Jules]

a step forward Musky at least, still seems strange though I agree, why the sudden change? maybe just coincidence that the return spring has weakened a bit in conjunction with the high spot "alignment" 

[Rex]

Has the bike been parked up somewhere, someone's nudged it with their car and it's fallen on the RH side, then they've hurriedly picked it up and f*cked off without saying anything?

[muskrat]

G'day Fellas.
Nothing done over the weekend (funeral Friday, bike club AGM Sat/Sunday).
Will slap it all together tonight.
Jules, The old spring is stronger than the NOS spring. Still scratching my head as to cause.
Rex, when I'm out she never leaves my sight bar going for a beer or a squirt. Funny thing is it seems to have started after my emergency stop and hit the back of a trailer. I may have locked the back wheel a tad before pulling the clutch lever 
Cheers

[berger]

maybe the spring is the problem and making it stick

[muskrat]

G'day Bergs.
It sticks with both springs and with NO spring!
Off to work now but will tackle it tonight. Gotta finish it so I can get back onto the Cafe manifold job then the XT needs some electrical work and the new HD tanks need lining and painting.
No rest for the wicked, but it keeps me out of the pub!
Cheers

[sean]

wonder if a double gasket might help would give a bit more clearance if something is binding.

[Brian]

Just a thought Musky but maybe try loosening all the engine mounting bolts including the top and bottom one at rear of gearbox so the engine/gearbox is loose in the frame and then do them all up again.

it seems the only event thing that has happened is when you tackled the trailer, maybe that has given everything a shunt.

[muskrat]

G'day Sean.
I tried that but had the same result.
G'day Brian.
A good suggestion. I'll try that. It was only a soft "shunt" the forks and wheel are still true and I stayed upright.
The bugga was my phone must have jumped out of my shirt pocket. Got a new phone with the same # but lost all my contacts #'s. So for the last month if someone leaves a message (I don't answer if I don't now the caller) they get a message back "who the phu(k are you" 
Cheers