kickstart sticking

[muskrat]

G'day Fellas.
As the title says. A7 plunger. Recently the lever has been sticking down but only sticks the last inch or so of stroke. If I loosen the outer cover it's free. I tried putting in an extra gasket but when tightened up it still sticks. There is endfloat on the shaft and it's free in the bushes and I can't see any rub/wear marks.
I didn't touch the box with the recent motor rebuild and has been fine since I put new bushes and quadrant/pinion in years ago! I'm wondering if the sudden stop when I ran up the back of a trailer (at about quick walking pace) a month or so ago has caused it.
Any ideas?
Cheers

[RichardL]

In that stop, it would not have been engaged, I believe. That would make it an unlikely candidate, I think. Having had something similar when the bushing in mine got too sloppy, I would think that would be something to look for. When the problem finally got in the way of starting, I was surprised that I had been able to kick it over at all for months before.

Riochard L.

[limeyrob]

That rings a bell, I know I've had this problem in the past.  I think the bush wears unevenly, could there also be any corrosion on the spindle?

[muskrat]

Thanks Fellas.
The shaft is pristine. Will look at the inner (bass) bush tonight.
It's not stopping me riding just a PITA to flick it back up.
Cheers

[Swarfcut]

  Worth a look to see if somehow the shaft has acquired a bow which tightens up against the bushes in a certain position. A strange fault, having been OK up to now. Is the return spring pushing it sideways to catch on the inner covers? A washer each side of the quadrant could be a fix.

 Swarfy.

[muskrat]

G'day Fellas.
First I'd better correct my previous post. The inner and outer bushes are steel. There is a little wear on the shaft where it passes through the outer bush approximately 0.002".
I've had the cover on and off 100 times this morning to no avail  . The shaft is straight (within a thou). I swapped out the pattern spring for a NOS spring and gave it maximum preload (two turns more than the pattern), same. Tried it without the spring, same. Made sure the dowel holes are clean. Same. After lunch I'll remove the ratchet pinion and last resort remove the quadrant from the shaft. The quad is a light press fit on the shaft. 67-3178.
Spanners ready to fly across the shed.
Cheers

[limeyrob]

This is really annoying me on your behalf. I know I've had exactly this problem and I know I've fixed it but I can't for the life of me remember how.  All I can remember is 1 its wasn't obvious, and 2 its was an easy fix once I found it.
I know that it terms of help this is about as useless a reply as they come

[berger]

Musky take the kickstart lever off, clamp some mole grips onto the shaft and turn it fully until it stops and see if if sticks without the lever on. if it does go to the pub

[muskrat]

G'day Fellas.
Too bl@@dy hot in the shed 36C. Took the ratchet pinion off, same. Took the nos spring off, same. Polished the shaft, same.
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.
I'll make some new dowels as the originals are looking a little sad.
GMF'd
Cheers

[berger]

musky 10thou thicker gasket then

[muskrat]

G'day Bergs.
I use a 0.8mm gasket and early on in the problem I tried two so that = 60 thou  but didn't change anything
I just can't understand why it's changed more or less overnight.
Cheers

[Sakura]

Yes, I've had this and yes, I can't remember the solution! Is the problem in the ratchet gears? They've been known to crack and jam. Assemble the case without the ratchet gears and try the quadrant. If it doesn't jam the problem could be the ratchets. They also sometimes jam on top of each other.

[Colsbeeza]

Hi Musky, Sakura may be on the money. I found my ratchet was sticking at the bottom. The kickstart ratchet pinion teeth were very worn and the kickstart quadrant was jamming. It was about 5 years ago so relying on a fading memory. I used other parts from a spare gearbox.
Col

[muskrat]

G'day Sakura/Col.
I tried it with the ratchet pinion removed. Same problem.
I'll get a pair of bushes but in the mean time I'll just give it a nudge with my toe to bring it back up. Lost too much riding and too much time spannering.
Cheers

[Colsbeeza]

Yeah Musky, I should have read your efforts better.