Kickstart lever freeplay

openroad · Feb 19, 2011

I've gotten the old girl started after, oh, about 28 years, still some carb problems to be sorted out. But I seem to remember alot more engagement of the kick lever. I don't get much engine rotation, it really doesn't spin the engine until almost at the bottom of the swing. The first picture shows the lever at rest, the second shows where the actual engagement starts and it is actually spinning the engine. I know it's a bit off spline. Shouldn't it start earlier in the swing?

MIKE

Josh Cox · Feb 19, 2011

Mike,

That engagement looks about right to me, I am no expert.

Take the kick starter off the spindle and turn it clockwise up to a higher static position, look at other bikes and you will see the kick starters often sit in their static position up near the top forward bolt on the "Z" plate.

As can be seen here:

If its all too hard you can pack the bike into a box and I'll take good care of it for you............

Hobot · Feb 19, 2011

A right runing Cdo can be started with the lever down that low, but maybe not after 25 yr setting about. The reason it was moved was to stop the back of calf poking. If ya grind down the stops on the lever and peg ya can get it to fold up enough to miss calf yet still engage for a full stomp down. Ugh, it may also have been the only position the booger-ed splines allowed, ugh. You'll find out, once you are able to remove the kicker, which with booger-ed splines can be a booger boo.

I'd heard it said a Commando is never ending project.

nortriubuell · Feb 21, 2011

+1 with hobot ! I would make darn sure your kickstart is tight on the splines, and as Steve says hopefully the splines aren't all buggered ! It's a worthwhile mod to remove 1/16" to 1/8" off where the kickstart bolt clamps. I've seen too many Commandos that had the bolt all the way tight, and the gap pinched all the way closed ... and there was still slop with the kickstarter on the shaft. Hacksawing' a "sliver" of metal where the bolt clamps, will fix this so it can actually clamp tight; good luck !!!

I would also move the mounting of the starter on the shaft, so it looks like mine in the picture. Just my 2 cents trying to help a fellow ..."Nortoneer" .

cash · Feb 21, 2011

nortriubuell.

How did you get the chain to run passed that fat rear tyre?

Nice bike.

Cash

openroad · Feb 21, 2011

I pulled the lever off, splines badly trashed, but I have spun the lever around higher, like yours nortriubuell, and tightened the crap out of it. So far it's working way better, and once I get to it I'll replace the lever. Tranny splines are good to go.
Much easier to start this way, though I'm still fighting the carbs, mostly me fumbling around but got some good tunes on and it's warm in the shop.
Thanks everyone!

MIKE

nortriubuell · Feb 22, 2011

Hey there "openroad', glad to hear your kickstart is working better now !!! And to "cash, it fits, but just barely ! I cant' fit the chainguard without cutting the inside out where the tire is. So, I don't install a chainguard when I run this 16" rim with fat rear tire. My chain clearance with the 16" tire is only 1/8" to 1/4" ... but since the chain only moves up and down (not side to side) it's a non-issue. I do like the look of the fat rear tire ... makes my bike look more "meaty" to me. However as my avatar shows, I currently have the stock 19" rear rim back on. In the spring I'm going back to the 16" rim with fat rear tire ... and will modify my avatar then. Cheers !

Josh Cox · Feb 22, 2011

The kick start pinions are usually hardened, the splines on the kick starter are by design the weak point, easier to change a kick start lever than a pinion....

When I brought my bike, some dick wad had put the lever on far too low and welded it on, an expensive repair....

openroad · Feb 22, 2011

I was wondering if there would be an advantage to getting MK3 lever, or sticking to this model.

gtsun · Feb 22, 2011

The MKiii lever gives more leverage & makes it easier to kick. Just don't buy any aftermarket ones. I have had two & they both were softer metal & the internal splines were not machined as well as an original one. I ended up buying a Andover one from Norvil I think & to my surprise it was a better made part. Not cheap though.

openroad · Feb 23, 2011

No, I just looked at some prices yesterday...YIKES!!! No wonder someone welded it back together. Gotta be some way to fix this piece of unobtanium and make it work again.

nortriubuell · Feb 23, 2011

Well, since it's already ..."bad"; you could modify it like a Triumph kickstarter is. By that I mean grinding a flat on the kickstart shaft, and then modify the kickstarter itself to accept a '"wedge bolt" (like the Triumph kickstarter). In my opinion, the Triumph design is much better, having no splines to bugger up even. I have often thought of doing this to one of my spare Norton AMC gearboxes, but just haven't gotten around to it yet. Certainly better than welding shaft and kickstarter together anyway ...

openroad · Feb 24, 2011

I don't know, hate to alter that shaft. Several off brands are for sale, Emgo for one from Commando Specialties. If it's not horrible, it would save over 100 bucks to use somewhere else on the scoot. i can get by with this one for a bit, it's my fault for not keeping it tight back in the day, I guess, it's a a little foggy looking back that far.

luthier · Feb 24, 2011

Just wondering if the dreaded layshaft bearing could be playing up and causing the low position of this kick start lever?

gtsun · Feb 24, 2011

If you want it I have a Emgo one from Commando Specialties that is almost new I will look up what I paid for it & come up with a bargin price.

swooshdave · Feb 24, 2011

gtsun said:
I ended up buying a Andover one from Norvil I think & to my surprise it was a better made part.

Why does that surprise you? Don't you expect Andover parts to be better?

openroad · Feb 24, 2011

luthier said:
Just wondering if the dreaded layshaft bearing could be playing up and causing the low position of this kick start lever?

I rotated it around to a higher position, seems to be holding position. I'm thinking it just got down there through sloppiness of the fit. But I worry about that, too. I didn't think the Mark 2's had a big problem with the late model Portugese layshaft bearings. But just from what I've read here.

gtsun said:
If you want it I have a Emgo one from Commando Specialties that is almost new I will look up what I paid for it & come up with a bargin price.

Did it hold up at all in use?

pelican · Feb 24, 2011

from the other threads on here the layshaft failure and kickstart lever falling is more evident while the bike is in gear

Kickstart lever freeplay

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