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Slipping Kickstart Lever

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Slipping Kickstart Lever

Post  MrTweedy on Fri Oct 23, 2015 2:32 pm

Hello all.

I'm currently working on a Villiers 6E engine but the kickstart is slipping due to worn splines. It's definitely the kickstart lever that's worn and not the shaft.
Is the anyway of fixing a slipping KS lever or will just have to get a new one?
I don't really want to buy a brand new one as it'll stick out like a sore thumb on very used looking motorcycle.

Any help appreciated.

Regards

Matt


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Kick start

Post  kerabo on Fri Oct 23, 2015 3:37 pm

Make sure there is a gap to clamp . If the sides touch it will never be tight. Put a good strong bolt in and do it tight. It's a shame to butcher the gearbox spline just to fix this .
Regards ken
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not the bodge it sounds !

Post  piston 197 on Fri Oct 23, 2015 5:01 pm

Temporary fix, !
place kickstart in correct position , tighten as much as you can, weld onto end of shaft,
when you find a decent kick start grind off weld from end of shaft, splines will not be affected and a new kickstart can be fitted
DO NOT drill kick start and shaft and insert a pin, ( it will snap sometime in the future)
Do NOT drill in from end and insert a screw ( it will mess up shaft for future use)
DO NOT grind a flat on shaft and insert a cotter pin ( see above)
JH
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Re: Slipping Kickstart Lever

Post  Jack Clegg on Fri Oct 23, 2015 10:10 pm

If the sides clamp up before it gets tight enough & providing there are splines left to engage, you can make room by removing K/S, clamping up tight in a vice, then pass a hacksaw thru the closed slot. You might get away with one cut. Otherwise there is no shortage of gammy old Kickstarts lying about. TTFN Jack
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Thanks.

Post  MrTweedy on Sat Oct 24, 2015 9:34 am

Thanks for the advice. There is still a gap once tightened but I don't think I've been able to tighten the pinch bolt enough to over come the worn splines. Yesterday I sheared the bolt while putting an bit of pressure on it.
I think I'll try a brand new nut and bolt and tighten it as much as I can.

Thanks

Matt



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Kick start

Post  keith.hodgenia on Sat Oct 24, 2015 12:34 pm

Hi matt, you could try cleaning up the splines in the kick start lever with a needle file.

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Re: Slipping Kickstart Lever

Post  MrTweedy on Sat Oct 24, 2015 4:19 pm

Thanks Keith.

I was having a go at that today. Hoping that and a new stronger pinch bolt will help.

Matt

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kick start

Post  kerabo on Sat Oct 24, 2015 4:41 pm

You could clear the hole with a drill so its not bending the bolt.
Regards Ken
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Kick Start lever

Post  tbird on Sun Oct 25, 2015 8:48 am

If the lever has been chromed then a drill and hacksaw will not be of use, chrome is hard so the best thing to open up the slot or drill out the bolt hole is a Dremel.

Graham
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Re: Slipping Kickstart Lever

Post  Ted Snook on Sun Oct 25, 2015 11:23 am

If you extend the slit with a hacksaw into the shaft of the kick-start lever by 1/2" or so, diametrically opposite the present slot, it will allow the clamping screw to tighten with a greater force on the splines. Because it will allow more clamping action, you will probably have to increase the existing slot slightly, as it will now squeeze much tighter.
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Kick start

Post  Steve drew on Sat Oct 31, 2015 7:38 am

Hi Mat, I had a similar problem on an old RE, the cause initially was the engine being a bit tight, once I cleared that problem the damage had been done to the Vick start which I was informed was a softer material than the shaft on purpose. Once I cleaned it all up I used a 2 pack instant metal product between what splines were left, tightened it all up the best I could and it worked well until I got a suitable replacement. The old one came off a treat with a bit of heat.
Steve

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