Just rebuilt an M20 last night and have replaced the kickstart Quadrant & Spring but now its all together I went to kickstart it for the first time and still there is a ratchet type action where the gearbox is not turning the engine over every kick and something seems to be slipping, would this be the quadrant or is there something else inside that would cause the occasional ratchet/slipping action when under high load to try and get it started?
Ned the bike running for the morning but knackered after working all hours on it over the last week and need to get this sorted?
Assuming all else in the primary drive and clutch/transmission are correct; K/S lever should only "ratchet" upon return... If the engine is not engaged as the K/starter is depressed, yet the K/S ratchets upon return, then then driven piece ( #122 in the diagram) of the ratchet mechanism affixed to the end transmission main shaft is not being engaged....Why? At least all this can be reached through the outer transmission cover.
From your text, it appears that the K/S engages partially, or only sometimes. If the K/S quadrant has worn teeth, it will jump or not engage until well through the lever stroke. If outer case boss is cracked around the quadrant, it can allow the quadrant to shift position and the K/S to slip as well....look for a cracked outer case around the bottom of the K/S casting boss.
Also, is the clutch slipping...? This would account for what you seem to be describing...
Is it possible it is the cush 'knuckle' drive on the crankshaft end slipping over due to the nut not being tight enough, rather than the gearbox? Primary cover off would allow observation of this.
