broken kick start return spring in RGS

[lillygunny]

My return spring broke today and I have not taken anything apart or ordered the parts yet. I have done a search and read that I need to remove the gear box cover leaving the shift lever and kick starter intact, but I don't understand how to replace the spring so it is under tension with the kick start lever in the start position. It is not clear to me why I use the clutch lever to hold the kick starter.

Thanks for any help.

Ron

[bsa-bill]

take the cable out of the clutch lever ( on the gearbox cover), take off the inspection cover from the gearbox cover, this will allow the clutch lever to swing out and catch the kick start lever stopping it from unwinding.(it will unwind a small amount)
When replacing it all you only need to pull back the kick start lever a little bit as you push the gearbox lever back on.
Not difficult to replace the spring as you will see when you get it parted
All the best with it

[lillygunny]

Thanks Bill, right now the kick start lever drops all the way down and does not come back up. Do I put the kick start lever in this position before I install the new spring or after? That is what I don't get.

Thanks a million.
Ron

[Beezageezauk]

Hi Ron,

Obviously your kickstarter goes down to the bottom because the return spring is broken.  When you replace the spring you need to tension it by turning the kickstarter anti-clockwise and then prevent it from unwinding by moving the chrome clutch operating arm outwards and then allow the kickstarter to rest behind it so that it acts as a temporary stop.

When you are refitting the outer cover you will need to push the kickstart rearwards just past the vertical position to allow the kickstart mechanism between the inner and outer covers to line up.

Check the kickstart operation before you fully tighten the outer cover and again when the outer cover is fully tightened.

Beezageezauk.

[bsa-bill]

Sorry Ron I completely lost the fact your return spring is broken - Beezageezauk has it right

[PaulC]

Hello everyone. This seems to have happened to me today on my Super Rocket and this post seems to provide a reasonable solution for me. Happened on the kick that started the engine and with the lever hanging down, there was a sound like slightly touching cogs. Lift the lever manually to upright and the noise stops. Gears engage ok, so I'm assuming just the spring. When the engine is stopped, the lever stays in the upright position (but I don't know why).

Am I right in thinking the replacement can be done through the oval inspection cover without further dismantling? Also, I'm assuming I'll have to remove the right hand footrest to allow the lever to be turned far enough anti-clockwise to be held by the clutch lever. Do I detach the clutch gable just by manually moving the arm towards the centre of the bike? Should I grease it when I re-fit?

Hope that's no too many questions and none are too stupid.  Thanks for any replies.

Paul

[RichardL]

Paul,

You can't fix it through the oval inspection cover. The gearbox cover will have to come off. The springs are available, but it may be a case of the spring not engaged with the starter quadrant (the partial sprocket that engages the gearbox main-shaft pinion behind the cover). If the spring is not engaged, it could be a case of the previous owner using the wrong spring, or, less likely, the wrong quadrant.

Richard L.

[beezermacc]

You need to remove the gearbox outer cover (not just the little oval inspection cover). The outer cover can be removed with the kickstart and gear lever in place. Remove the four nuts and the screws and pull the whole lot towards you with kickstart and gear lever held in the casing. You don't need to undo the small nut near the kickstart lever as that is to hold the spring, nor the small screw above the speedo drive as that holds the drive in place.

[duTch]

 Might be a good idea to drain the oil before you start...

[RichardL]

 Might be a good idea to drain the oil before you start...

Uhh, he means gearbox oil.

[PaulC]

Thanks for your replies. More involved than I'd hoped!

So the lever and spring are attached to the inner side of the cover and the whole kickstart assembly will come away with the cover? If so, how do I do the tensioning bit using the clutch lever?

Thanks
Paul

[PaulC]

Just opened my Haynes manual at p59 and I get it, now.

Thanks for your help.

Paul

[duTch]

Uhh, he means gearbox oil.

 Ah yeah- I know it kinda obvious, but.....

Paul, it's all fairly easy....that 'sound of sllightly touching cogs' would've been the return ratchet, and the reason it stayed up is because the corresponding start gear on the mainshaft was holding it- if you'd pushed down, would've turned the engine over.

[RichardL]

If so, how do I do the tensioning bit using the clutch lever?

The clutch lever is flipped around to keep the kickstart lever from springing forward when the gearbox cover is pulled off. Since you have no working spring, this is not an issue. And, yes, manually moving the clutch arm toward the center of the bike is the way the cable is released from the arm.

Richard L.

[PaulC]

Thanks all.

I will dismantle at the weekend and see what I find inside before ordering the spring and new gasket.

Paul