How to remove the kick start?

[stuart-glos]

I have failed to remove the kick start from my 301 project.

I have loosened the lock nut and freed off the washer, sprayed the whole thing with WD40 and tried to ease out the cotter pin with a hammer but it's stuck.

Any suggestions please?

thanks

stuart

[Louis Mair]

I recently had to remove one because the kickstart lever was broken. If you don't really have to remove it you could leave it alone.
Removing the casing from the machine was necessary on my one. As I had already broken the threaded bit of the retainer pin it was relatively easy to drill a medium-sized hole in the bit that was reluctant to move. I then applied hot water to the kickstart lever and hammered a drift against the reluctant pin (remains of). You need to hold the lever away from the stop, which doesn't help.
I had worked out a scheme to drill and tap from the other end (front end) and use a screw and spacer to pull it. This didn't prove necessary but it certainly does not move easily!
It is considerably easier to re-assemble the whole thing. I replaced my bits from spare TS parts. The kickstart assembly does not seem to change over many years. It does have an annoying habit of not engaging from time to time. I turned the smaller of the two springs around which may be why it is working so well at the time of writing.
Good luck!
Louis

[radiograf]

Which way are you trying to remove the pin? Tap the tread end as it is a tapered pin, and the lock nut actually draws the pin into the lever to secure it. If that fails try a little heat from a blow torch or heat gun.

[Louis Mair]

I was hoping someone had a simpler alternative. The pin you are trying to move is soft compared with the two hard bits that it holds together. My second attempt was more successful than the first.
In order to protect the weak, threaded part of the "splined bolt" or "kickstart retainer bolt" I drilled and tapped a short length of 8mm steel rod with an M6 female thread. If you screw this on with two spring washers you will be less likely to destroy the pin or bolt. It worked for me!
Good luck!
Louis

[Trogolodyte]

If you use a blow lamp, dont heat the pin itself you dont want that to expand!!, apply it to the kickstart lever near the engine end not around the pin.