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#701968 - 07/16/17 9:51 pm 1968 500 jammed kickstart  
Joined: Sep 2009
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SEATTLE GS Offline
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SEATTLE GS  Offline
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SEATTLE WA
this is a friend's bike...the kickstart jams when trying to kick it over. If he puts it into gear and bumps it, it will free up but quickly jam again. What parts would be necessary to solve this problem? The kickstart assembly is very much liker a Norton so I think the pawl is the problem but how about the gear it fits into? any ideas/

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#702001 - 07/17/17 11:38 am Re: 1968 500 jammed kickstart [Re: SEATTLE GS]  
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paulberry Offline
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South Lincs

It should be fairly obvious what's jamming by inspecting the gears, selectors etc. Your'e going to have to go in there to fix it anyway.

Cheers Paul


1969 T100S
1955 Tiger Cub
#702010 - 07/17/17 1:27 pm Re: 1968 500 jammed kickstart [Re: SEATTLE GS]  
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russrudolph Online content
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russrudolph  Online Content
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USA, WA state
My 1970 t120 engine does the same thing. Annoying but still usable. Will watch this discussion.
Dave hope to see you at Tenio swap meet again. Russ

#702017 - 07/17/17 5:17 pm Re: 1968 500 jammed kickstart [Re: SEATTLE GS]  
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SEATTLE GS Offline
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SEATTLE WA
Its the time frame ...I need to get it done in a week

#702105 - 07/18/17 10:31 am Re: 1968 500 jammed kickstart [Re: SEATTLE GS]  
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NickL Offline
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NickL  Offline
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Aus
It's normally the kickstart quadrant being worn that does it.
That's not to say anything else isn't worn as well.....................



#702116 - 07/18/17 2:38 pm Re: 1968 500 jammed kickstart [Re: NickL]  
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russrudolph Online content
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USA, WA state
Thanks

#702146 - 07/18/17 9:39 pm Re: 1968 500 jammed kickstart [Re: SEATTLE GS]  
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RF Whatley Online content
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RF Whatley  Online Content
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North Georgia, USA
There is no separate kick start quadrant on a T100, like there is an a 650/750. It's made onto the kickstart shaft.

So I'm thinking you'll need the k/s shaft, the needle roller that goes inside the shaft (if not included), the k/s pawl, the 1/8" dia split cotter x 1" long (or longer), and maybe the k/s return stop plate. You'll need the 2 cover gaskets and some gear oil. I have never seen the first gear damaged from a sick k/s pawl.

Since you have to go all the way inside the g/b, I'd also replace all the coil springs in the shifter mechanism and cam plate plunger if you don't know them to be less than 20 years old. Replacing the o-ring and seals on the gear shift and k/s shafts wouldn't be a bad idea either.


If it's not the pawl causing the issue, then it's usually damage caused by allowing the k/s lever to fly back up. The T100 return stop boss is very small and often mushrooms or peens over in strange ways when owners watch too much West Coast Chopper.

bigt


Don't hide 'em, Ride 'em !!

RF Whatley
Cornelia, GA

"Shop Boy" at Rodi British Bikes
#702162 - 07/19/17 12:32 am Re: 1968 500 jammed kickstart [Re: SEATTLE GS]  
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SEATTLE GS Offline
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SEATTLE WA
The problem is...the needle bearing in the kickstart shaft completely shattered. Also, it seems to be impossible to remove the needle bearing so we are buying a new shaft, bearing, pawl, and washer. It is quite an effort to change all this stuff out.

#702173 - 07/19/17 5:25 am Re: 1968 500 jammed kickstart [Re: SEATTLE GS]  
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NickL Offline
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NickL  Offline
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Aus
Screw a large tap into the bearing and pull it out, once you've dug the rollers out.
I thought you may be lucky and get away with just the pawl or shaft.



#702193 - 07/19/17 10:43 am Re: 1968 500 jammed kickstart [Re: SEATTLE GS]  
Joined: Dec 2006
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paulberry Offline
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South Lincs
Originally Posted by SEATTLE GS
The problem is...the needle bearing in the kickstart shaft completely shattered. Also, it seems to be impossible to remove the needle bearing so we are buying a new shaft, bearing, pawl, and washer. It is quite an effort to change all this stuff out.


http://www.britbike.com/forums/ubbt...;Main=59371&Number=544278#Post544278


1969 T100S
1955 Tiger Cub

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