Hitchcocks Forum

My 350 bullet has always done this occasionally. If you set off more briskly than normal, the kickstart lever will pivot itself down about halfway then pop back up when you come off the power (usually hitting you on the back of the boot as it comes back up). Only ever done it in first and more often when the engine is really hot.



Out on the 612 for the first time today, I noticed it does the same thing pretty much any time you wind-on the throttle (presumably delivering an equivalent amount of torque to a racing start on the 350). Noteably, this bike has a sealed 4-speed gearbox with EP90 in it rather than the standard, grease-filled one on the 350. Given the 350 does it more when hot, I wonder if the viscosity of the lubricant is a factor?



This leads me to the conclusion that this is a "feature" of albion 4-speed boxes? It's a bit annoying, I can hold it up with my heel and have got used to doing it on the 350 when I want a fast getaway but it's a pest doing it every time you open the throttle. Anyone know what causes it and if there's a fix?

What you describe is caused by friction and drag between the layshaft end and its fit inside the kickstart shaft bushing and, as the load imposed on these parts increases, so the problem becomes more apparent. Thinner oil might help.

My year 2000 Bullet 500cc did the same for a long time. I think it has settled down now. -Chris

I wonder if it would be improved if I got my mate to turn me up a bronze bush for it. I see from the parts book they have a steel one as standard. Difficult to see from the pics of that bush but you might even get a caged needle roller in there? (although mayhem would ensue if it came apart!)

Late Triumph 500 twins used needle roller bearings in their kickstart shafts, rather than the bronze bushes that were used before them. the other ends of their layshafts also used them, so in theory, it could be done.

I'll have a measure up next time I have one apart. (or order a spare bush and measure that).

Hi, it could just be a weak return spring, try securing it to the bottom right inner screw and not the bearing cover screw and see if that improves it. Vince

When it started to happen on my 350, it was bearing failure I am afraid.

It's been doing it on my 350 gearbox for over 70,000 miles.

@ vince, yes I did also wonder about the return spring and that would be comparatively simple to try and not disastrous if it broke providing I have a bit of string or a bungee.



I have also considered simply making a hook/loop/bungee arrangement to hold the kickstart in the up position. I have to reach down to pivot the lever out anyway when starting it.