Kick start not returning fully

[Andie]

Hello.

Started up the LI series 3 and the kick start is not fully returning.

I split the case. The pin sometimes mostly returns fully, sometimes not, even so the kick start stays a few cm short of the rubber stop.

pinion pin.jpg

pin 2.jpg

big gear.jpg

There is some wear to the Kickstart plunger part.

Have stepped away for today. Any advice gratefully recieved. The big gear seems fine, just some light contact wear, i hope.

Does this look like a plunger replacement is needed?

Many thanks!

[Warkton Tornado No.1]

I’ve never seen the wear on a kickstart shaft like that! It may be ‘historical’ from it’s previous life but - presuming the bushes are not worn & no excessive axial play - I would remove the plunger, register pin & plunger spring & reassemble to check that all operates as it should prior to proceeding. Personally, I wouldn’t be able to resist dressing that worn face because it looks so gash! Obviously there should be no contact & - for good measure - axle assembly should rotate freely with the kickstart lever in any position, though you will need to ensure the lever & shaft are assembled spline-wise correctly. It’s always worth marking the shaft with a centre dot or hacksaw slot in line with the lever’s cut-out in any case I feel. By the looks of it, it would hardly be a surprise if swarf isn’t causing the plunger to bind

[Andie]

thank you.

" I would remove the plunger, register pin & plunger spring & reassemble to check that all operates as it should prior to proceeding"

I will look to that.

kickstart parts.JPG

and look to replace these parts? maybe with MB / upgraded parts.

The kickstart not returning is a concern, of course. It may have slipped. I don't think it did.

many thank for advice, as always.

[Warkton Tornado No.1]

thank you.

" I would remove the plunger, register pin & plunger spring & reassemble to check that all operates as it should prior to proceeding"

I will look to that.

kickstart parts.JPG

and look to replace these parts? maybe with MB / upgraded parts.

The kickstart not returning is a concern, of course. It may have slipped. I don't think it did.

many thank for advice, as always.

I would just try & utilise good OEM components. Better to fit components of known quality & dimensions IMO.

I am not alone in fitting ‘upgraded’ components & having issues. Some of us took it for granted that the special sprocket drive bolts would be wonderful, only to experience weird drive issues. They looked fantastic, extremely well finished & shiny. What could go wrong? In the event, no doubt in trying to incorporate improvements in ‘Mark’s way’ they were a tad too long & consequently allowed the drive cams to override each other….