1962 A50 - Kick start non return when outer cover is tightened

[blackeyeian]

Hi All  I ahve just replaced the inner timing gasket, re assembled everything back as it come off. 
When I tighten the outer case fully the kick start binds and wont return.  If I loosen the rear bolt 1/2 turn, the kickstart frees up to normal.
I have reset the return spring 10 times but no change.  Just to try it - I turned the  kickstart spring retaining lug round so the lug was facing the engine as I thought this was binding. 
It worked for 10 miles then reverted back to binding again. 
Is it possible that the outer cover is warped and the kickstart shaft is binding in the hole restricting its movement.  As there is no oil in this section, can I open up the kickstart hole a little without any problems? 

Any suggestions would be most welcome.  Regards Ian

[DAVE BRADY]

Hi Ian,

Are there any marks on the inside of the outer cover to show which part is binding?   

Dave.

[royblackburn1@btinternet.]

If I can remember right this happened to me, make sure you gently tap the kickstart quadrant fully home in its housing I found when fitted the outer casing it was rubbing on its shoulder and would not let the kickstart return, hope this helps. Roy

[wardy]

Had the reverse problem on my A65 - in my case the kickstart bush was protruding out of the outer case by 2-3mm. Check the bush is flush in the case (may be protruding on the inside)

[blackeyeian]

Thank you for the messages
The inside of the outer cover has been ground away to make clearance - The only mark I can see is inside the Outer Cover kickstart hole - towards the back screw.  Maybe the outer cover is being distorted when tightening - Would it affect the cover if I ground a little of the kickstart hole away for clearance?       
The Kickstart quadrant is fully home at the start of re fitting.

[DAVE BRADY]

Hi,

A bit of an obvious question but did it do this before you did the gasket?  If not then something is not quite sitting right.  The spring and plate can be fitted quite easily when the plate lines up with the flats on the kickstart but it needs to turn past this first position to the next position, so that the tang turns back almost to its original position.  I think the space in the outer cover is deeper in the upper part.
Grinding the cover will only relieve a symptom and not the cause.

Dave. 

[blackeyeian]

Hi the Kickstart shaft if fully in line with the hole in the tang - the faces are flush - there is no overhang on the tang.

[craigc11g]

not enough turns on the kick start loading the spring before pushing the outer cover on sounds like .