Folding kickstart woes

[BrianS]

I treated the A10 to a folding kickstart from Steve at Feked but can't get it to fit!

I have tried three new 3/8ths cotter pins (the last one was from Steve hisself so as to make sure it was 100%) and they all just slide right through and don't catch on the kickstart shaft cutout.

The cotter pins are all a tight fit with the original kickstart to the extent that very little thread comes through so I am thinking it's not a problem with the shaft. Does that sound right?

I don't want to make a fool of myself (again!)  but am thinking that the cotter pin hole in the new folding kickstart might have been drilled a little too far away from where it contacts the shaft.

Any feedback appreciated.

Brian

[a101960]

but am thinking that the cotter pin hole in the new folding kickstart might have been drilled a little too far away from where it contacts the shaft.

I think that you are right in your assumption. The cotter pin should be a tight fit in the kick start hole. I think that you should return the kick start and source one from some where else.

[dave55]

Is it a tapered cotter pin with a flat on it ?......You are lining the flat up with the flat on the shaft ?

[BrianS]

Is it a tapered cotter pin with a flat on it ?......You are lining the flat up with the flat on the shaft ?

Hi Dave

It is this one https://www.feked.com/kickstart-cotter-pin-triumph-and-bsa.html

The main body of the pin isn't tapered - 9.45mm along its length.

When I line up the pin with the flat on the shaft it pops in one end and right out the other 

Brian

[dave55]

So it has been drilled right through as if for a bolt ? Surely if it was for a cotter pin it would have a big hole one side and small clearance hole on other for the threaded bit ?

[BrianS]

So it has been drilled right through as if for a bolt ? Surely if it was for a cotter pin it would have a big hole one side and small clearance hole on other for the threaded bit ?

Both the original and the folding kickstart have holes drilled all the way through as if for a bolt.

[dave55]

So what did the original one have in it ? 

[Greybeard]

So it has been drilled right through as if for a bolt ? Surely if it was for a cotter pin it would have a big hole one side and small clearance hole on other for the threaded bit ?

No, the hole is parallel, the cotter pin is also parallel. It is tapered to engage with the flat on the shaft. See picture 1

What do you see when you look through the hole? Can you see the flat on the shaft coming into the hole? As in picture 2

[Derby Rob]

i think i had a problem like this when i restored my swing arm a7, i think the actual shaft was worn .If my memory is correct i wrapped a small piece of shim (a bit of coke can ) around the shaft so the the kick start was a tap on fit with a rubber mallet ,then the pin fitted ok

[Tomcat]

[quote} but am thinking that the cotter pin hole in the new folding kickstart might have been drilled a little too far away from where it contacts the shaft



Yes you are correct Brian, I had exactly the same problem on a part from DF.  Sent it back and bought the correct part from Beezermac. Looks like a bad batch of kickstart levers are doing the rounds.
cheers TC

[BrianS]

[quote} but am thinking that the cotter pin hole in the new folding kickstart might have been drilled a little too far away from where it contacts the shaft

Yes you are correct Brian, I had exactly the same problem on a part from DF.  Sent it back and bought the correct part from Beezermac. Looks like a bad batch of kickstart levers are doing the rounds.
cheers TC

That is interesting TC - and a tad re-assuring in that it may not be me doing summat wrong!!!!   Anyone else experienced a similar issue please? Just working out how best to convince the supplier of said folding kickstart that he is selling faulty goods. I would have thought that the fact the old kickstart fits fine should be enough?
Brian

[trevinoz]

Yeah, I had the same on a bike I was fixing for a friend. Couldn't see the problem until I tried another lever.

[muskrat]

Yep, me two. Mine was bought 6 years ago. Mine might not be quite as bad in that it wont go right through but doesn't have much adjustment. I bodged mine by gluing a piece of tin to the flat of the shaft.
Cheers

[KeithJ]

I have also had issues.  I found the cotter pins vary and that was my problem.  One company supplies the pin with a metric thread and imperial hex nut!  They said it was to make the threaded part stronger which I guess it does.  Also the threaded part of the cotter pin is offset to the body of the pin.  I ended getting my cotter pin from George Prew and it worked for me.  Good luck and hope 2017 is a good year. 

[chaterlea25]

Hi All,
Way way back when cotter pins were available in at least three different types, shallow, normal and deep mill, to take in the variations in shafts and cranks
The thread on old british cotters was 17/64 x 26 
Dont ask me how I remember all this 

John