Hitchcocks Forum

Hi all. When I rebuilt the gearbox on my 1996 535cc, in my ignorance, I undid the one nut that shouldn’t be undone and moved the kickstart crescent from its position holding the pinion closed. Since I haven’t seen a picture showing where it should be, I’ve been guessing where it is correct – see the attached image (also in my photobucket account under ChrisD200).



But I guess I am still wrong because the kickstart lever moves ~30degrees from the vertical before biting on the high gear ks pinion (no, it is a new and undamaged pawl). This means the kickstarter cannot turn the engine far enough to get to the next TDC to fire.
Can anyone show me an image of exactly where the crescent must be fitted, or tell me how to set it up? – yes, I am aware I cannot adjust it too far before it wears itself away through ratcheting on the pinion inner teeth. Can anyone advise if the 30degree free travel of the ks is too much?
Thanks, ChrisD

Chris, is that a new kick starter shaft, if so that is just a bit of Indian quality control you have to fix with a grinder. The pawl has to come around under the half moon to close the pawl up so it doesn't ratchet, and the stop is just past the end of the tip of the pawl, that has to come around up against the half moon

I had this when I replaced the pawl. As Norm says, it should park under the crescent. If I remember, I had to massage the new pawl and the crescent a bit with a grinder. Don't reply on just "cocking" the crescent; it might let the pawl park but will soon move back in use.

Guys, thanks for the comments. That kickstarter image does not show the closed position, unfortunately I didn’t take such a picture. I am aware that the pawl goes under the crescent, held down by its 'points' – if it didn’t, and was in the resting position as the image shows, then I’d never be able to start the bike anyway.

But, how much movement of the kickstart lever should there be before it starts to turn the pinion? Is my 30degrees too much? There is another point after ~10degrees when the pawl touches the gear pinion – is that where the kickstart should start to turn the pinion? In other words, should it be 10degrees or 30degrees movement before the pinion turns?
ChrisD

Chris, 30 degrees to bite seems a bit excessive.

I wish i had a box in bits to have a look but can’t help at mo..

Forget the pawl for a moment and refit the original shaft, now look for the witness mark where the old shaft used to hit the stop plate..

Adjust the plate to match the shiny mark on the shaft.. Should give you a starting point when you refit the new shaft..

Only picture i can find is a next to useless photo copy of Don Morleys rebuild article..

Your plate hasn’t been fitted back to front has it?? just wondered why the rust marks when it should have been greasy on that face..

My kickstart starts to engage at about 20 degrees, maybe a little more, but about the same as the AMC box on my AJS. I may be wrong, but it looks to me as if your pawl isn't quite lifting high enough. May need a bit of 'tuning' at the pivot, or possibly the plunger is sticking a bit and may need filing slightly.

As you can see from the pic Gwilly put up the pawl has to clear the half moon before it can open out fully and that is probably 20/30 degrees

Just measured mine (roughly) Seems to be about 15 deg.

Thanks Gwilly for that image. It is clear that mine is not set the same. So, tomorrow, I will FIX it. Fortunately I gave the box sealed bearings and so draining the oil+Molyslip is easy and not messy.
Thanks PeteF and Winkie – you’re comment on the 15degrees seems to fit with my latest measurement that there is a point at ~12degrees where the pawl just touches the pinion but not enough to catch – so that’s the aiming point. See the image in photobucket chrisD200/Bullet 535cc Gearbox and (hopefully) attached below.

Cheers, ChrisD

Perhaps the "point" of the crescent needs relieving to allow the pawl to escape slightly earlier.