Having Thought the 5 year Restoration of My M20 was Complete I appear to Have Fallen at the Last Jump The Kick starter will not turn the engine over indeed it appears Jammed but when the clutch is pulled in and using a C Spanner on the Shock absorber Nut the Engine moves Freely with the Outer Gearbox Cover removed it is Possible to easily turn the engine & Gearbox over using a spanner on the Main shaft Nut But the Kick Start Lever refuses to move it was suggested that a Change of the Kick Start pinion may help but despite fitting A new Pinion it remains Unchanged Any Suggestions ?

email (option): grumpy.moran@gmail.com

Hi Ron...Firstly...Is your kickstart ratchet pinion NOS?...If you are unsure check the overall profile of the teeth carefully...There are Indian replicas about that are variable....

If you are satisfied the gear is OK there are a couple of other things you can look at...

Check the amount of wear on the bush that fits through the gear...A lot of 'slop' there can allow the ratchet pinion to 'tilt' a bit and affect the mesh of the teeth...

Likewise the quadrant spindle and bush need to be reasonably good....

The first few teeth of the quadrant gear are reduced to help with initial engagement...Check that they are not damaged or badly worn...

This is a very common problem (feature?) with the swinging arm boxes but is less so with the earlier types...I have had the problem myself though a few years back...Ian

email (option): ian@wright52.plus.com

Ian
Thank You for this The Pinion was bought from a reputable UK Supplier and looks Ok & appears to match the Quadrant which is also Good but I did not check the Pinion Bush but will do so when the Temp warms up a Bit Temp got over 10C and A quick Check of the Bush Shows a wear mark were the Pinion Runs although its only .002 to .003 deep it Does allow the Pinion to wander around in good Aussie Terms Like a Male Member in A Bucket. Bush is Ordered we will see when it Arrives

Cheers
Ron

email (option): grumpy.moran@gmail.com

I can't think of one british bike that doesn't do it.No big deal unless the leading teeth are mangled.

I can't think of one british bike that doesn't do it.No big deal unless the leading teeth are mangled.[/quote]

:-) I imagine Ron might be seeing it as a big deal if he cant get his bike started! But granted, not a big deal to fix it.

email (option): cruiserchooserAThotmail.co.uk

Spot on it s only an issue if you don't want to start the engine and as for every British does it I am pretty sure the velvet the system would not do it but I have resolved it is just another trial that confirms the feeling you should not get involved in the restoration of a Basket case but vest le vie.

email (option): Grumpy.moran@gmail.com

Sorry to hijack the thread, but I've got the opposite problem with my Burman CP. The kickstarter seems fine three time out of four, but then every so often it will slip around with a horrible grating noise. I've checked everything, changed the pinions, spring and so on. The clutch is fine, brand new plates and springs. What could be causing this?