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/
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.
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.
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.
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.
|
| 
| 
