A 65 Kick Start Assembly

[Rob Neal]

Hi Again.  Having fitted the timing case the next job I'd planned to do was to fit the kick start return spring.  Simple? I should know better by now. After a whole afternoon of frustration I thought I'd better ask folks who know what they're doing rather than continue mucking about risking yet further blood loss from nipped fingers !!  There must be a straightforward way and I'm missing something obvious.  Main problem is the the spring distorts as it is tensioned and prevents the plate from engaging squarely with the two drive flats in the shaft.  It seems to me that there should be some form of sleeve sitting between the ID of the spring and the OD of the casing boss to reduce distortion.  Can't seem to find a parts illustration that would confirm this or not.  Anyone have any advice.  Thanks.  Rob

[Admin]

I found this method on the Forum (topic 1971 A65L Kickstart return Spring) which I have used a number of times and it works.

Put the spring onto the casing with the hook around the screw. Get a piece of thin strong cord, the stuff used on blinds is ideal. Loop the cord around the other hook on the spring and pull upwards, this pulls the hook on the spring up out of the way. Get the retaining washer and slide it onto the kick start spindle and put the flats into place. Lower the spring hook onto the the retaining washer hook and pull the cord out or cut it.
I hope that makes sense. it's straight forward once you have done it a few times.

[Mike Farmer]

 

I use a very similar method. except.I put the washer firmly in place then put a jubilee clip on the shaft to hold the washer in place. Then use the cord. Wear a glove because the cord can bite. remove the clip--job done. NORMALLY its a two minute job.

Mike

[Rob Neal]

Thanks for the tip.  I hadn't considered this approach.  If I'd only asked earlier I could have saved a whole afternoon of frustration.  On the upside though it was a good excuse for a couple of cans of beer to calm down later!!! And I can confirm the process described works.  As always, the advice is much appreciated.  Rob