About every 5 or so kicks on my A65, the teeth on the kick start spindle doesn't mesh quite right with the pinion on the mainshaft and everything gets all jammed up. Seems to be the last tooth on the spindle because it won't jam if I don't let it return all the way, but that is almost impossible to regulate unless I'm really thinking hard about it.
I have had it apart and couldn't really see anything wrong with it. This bike is a bitsa, so I'm wondering if the spindle and pinion are slightly different for different years and maybe I have a pair that doesn't like each other? Or is there something else that could be somehow catching up and I'm just missing it? The motor is a '68.
This not uncommon on these 40+ yr old bikes, in my opinion anyway. I have experimented with "fixes", which is a pain, because you have to assemble/dis-assemble to see if that works each time..... Anyhow, AND I WILL NOT PROMISE IT'S THE ANSWER, I did have some luck just grinding off the 1st tooth on the kicker shaft. It seems like that one gets flattened, and is the start of the jamming. The gear teeth on the trans get flat too, so try to find a better one if possible. My $.02.... KC
This has pretty much been an issue with A65s from day one. Ive heard all sorts of theories including it was a tooling problem that never got addressed and the gear center geometry didnt match up properly (wouldnt surprise me that much)
My personal opinion is that the gear modual (or what ever the technical term is Ive forgotten) is not sufficently course to prevent the crests of the teeth interfeering in some positions ie the crests lock rather than mesh properly.
Dont know the soulution apart from constant new bits ....Ive tried relieving the first tooth or 2 on the quadrant ...didnt make any diffrence,....its always been an issue .....the pre unit kick starts are much heavier and never seem to give a problem....just BSA cost cutting probably.
Im surprised there havent been more comments and theories on this topic
"There's the way it ought to be and there's the way it is" (Sgt Barnes)
the kicker on my A65 has never jammed...the one on my T120V takes 'spells' and sometimes will do it frequently but has not done so for the last couple of months ...when it does, i just cuss, put it in gear and rock the bike, and then it is free.....in other words, live with it.