!00 GS kickstart lever .......

[Roger Chatterton]

On my 100 GS PD 1994 model -

the kickstart lever is sitting too near to the frame/airbox, and is in fact resting against the airbox securing clips. Also the cotter-pin that locates the kickstart lever is in the wrong way up, ie with the nut on the top, whereas it should be the other way up, with the nut facing down - does that make sense ?

So, 2 questions -
is there any way to get the kickstart lever to sit correctly, ie about 10mm away from the airbox clips? and
if I remove the cotter pin, and re-position correctly, is the kickstart shaft likely to slip back to its default position, and thus be difficult to insert the cotter pin in correct position ?

Strange question maybe, but only just bought this bike, and never removed the kickstart before ( but have removed a gearbox before )! Is it likely that the rear cover to the gearbox might need to be removed ?

 

[Rob Farmer]

The kickstart quadrant is prone to loosing the top tooth and other chunks of metal. I've pulled mine this morning ready for a rebuild. I'll take some pictures of the kickstart internals as I go through it.

My cotter pin was in the same way as yours.

 

[Roger Chatterton]

Thanks Rob - be interested to see your pics. Although I would have thought that losing a "tooth" would make the lever sag down, rather then be tight up against airbox-probably bollox though !!
And you're now an Ambassador I read - status at last eh ? Are you going to the Belgium Airheads bash this summer ? Hope to be there myself.

 

[Rob Farmer]

A tooth missing wouldn't cause it to drop Rodger I just meant it was prone to breaking bits off. I've split the box so will get the camera out

 

[(RIP) Proff]

Cotter pin in the wrong way round

 

[Voyager]

Without wishing to pre-emp Rob

The kickstart mechanism is tensioned by a large spring and rests against a stop.

In use, the gear on the end of the moving arm engages with the input shaft and the quadrant behind it spins both the gear and the input shaft.

Nothing will spring back and go out of shape if you remove the kickstart lever.

The Cotter Pin is tapered and pulls tight against a flat on the shaft. It does sound as though your pin has been inserted from the wrong side.

I'll now get out of the way of Rob

Bob.

 

[Rob Farmer]

The roll pin at the bottom of Voyagers photo stops the kick start lever going to far back against the airbox. there's also another locking pin (in top circle) that needs to be intact to lock everything up before it rests against the roll pin. If the roll pins been battered or has come out your kickstart will go too far back.

The cotter pin will go in from either side so I doubt this is causing your problem but you never know. I'd have thought it was more likely that the roll pin will be crushed or missing.

 

[Roger Chatterton]

Many thanks for the advice and photos both - guess that's a gearbox out job then ?
Might not rush to do this job, or might bring the bike to the Wee Kend in Devon this Summer, ....Rob !!!!
Is the roll pin available as an easily replaceable part do you know ?

 

[Rob Farmer]

Might not rush to do this job, or might bring the bike to the Wee Kend in Devon this Summer, ....Rob !!!!

If things go to plan I'll be a long way away from Devon when the Airhead weekends on next Summer Roger.

 

[Essexadventure]

Mines like it too on my R100GSPD - thought they were all like it?? As it's doing no harm, think I'll leave as is!

 

[richie moore]

put the cotter pin in the other way up, it makes a big differance to the lever position, because of the taper, that should sort it, as long as the lever is not stuck on the shaft.