broken kick start return spring in RGS

[muskrat]

G'day Paul.
Have a good look at the kickstart quadrant and ratchet pinion and bush. A worn bush causes the ratchet teeth to miss on occasion.
As a side note. I was having that problem so I bought a new pinion and bush. I thought they had too much clearance from new and only lasted six months. I had to make a new bus 4 thou bigger on the OD to rectify it.
Cheers

[PaulC]

Well, I've started the strip down and as usual it hasn't gone smoothly! Ho hum. So far I have had to take off the silencer to get to the footrest nut. That is seized, so all I've managed to do is undo the left hand footrest nut. That means I can't get the right hand one off because I need to withdraw the bolt and nut to the right and the exhaust is in the way!

I have taken the clutch cable off, and the speedo cable, drained the oil and removed the three screws and lower two nuts of the outer gearbox cover, but I don't have the wherewithall to get the two top nuts off. I can't get a spanner onto then and the socket I have has is too thick to slip over the nut.

So here are my questions:

What spanner/socket do I need to get the top two nuts off?

How do I remove the Siamese exhaust? Do I have to split it first where the left joins in front of the down tubes? Do the fan-like surrounds have to come off too? Is it just a case of pulling out and then pushing in?

Thanks for any assistance.
Paul

[Topdad]

Hi Paul ,pretty sure you don't need to worry about the exhaust , re the nuts either a long nosed socket or abnormal one ground down abit for cleareance. Are you sure it's not crap stopping the socket give it a good clean and scrape with a small screwdriver should be easy then,keep at it ,bobh

[PaulC]

Thanks bobh.

I need to remove the exhaust because the right footrest bolt is seized so I need space to withdraw it with the 10 inch bolt still attached.

It's definitely not crap on the socket. It just has really thick walls and grinding may be the only option.

Paul

[muskrat]

Yep, that's special tool #123ABC ground down socket. Buy a cheap (whit/BS are not cheap down here) 11mm socket and grind it down. You need to split the pipes and they just pull out with the heatrings attached once the mounting hardware is removed.
Cheers

[PaulC]

Hello,

All back together again and no bits left over! Turned over engine and it felt good. Back to its old self.

Thank you all for your help and advice. Priceless.

Paul

[RichardL]

Hey, Paul, you gotta tell us what it turned out to be. Thanks.

[PaulC]

It was indeed a broken kick start return spring.

I still need to take her for a spin to make sure the gear change and speedo also went back together properly. In the end, the most difficult part was getting the kick start lever off the half moon cog. Hammer, wood and patience was required!

Paul

[KeithJ]

Yep, that's special tool #123ABC ground down socket. Buy a cheap (whit/BS are not cheap down here) 11mm socket and grind it down. You need to split the pipes and they just pull out with the heatrings attached once the mounting hardware is removed.
Cheers

I have found 3/8" drive sockets are more suitable than the 1/2" drive ones.  I have 1/4", 5/16" and 3/8" W in my tool kit.  They also work well for the head bolts which are inside the head.
ATB
Keith

[PaulC]

I did actually buy a 1/4" drive set and that saved me the trouble of having to grid a socket. It also proved useful in splitting the Siamese exhaust because it could reach parts the 1/2" ratchet wouldn't fit.

Paul