Installing kickstarter

[j2maria]

Being a newbie to Morinis I searched the forum to see how to install the kick start and found nothing. Several instances of "exploding" kick starter springs, and ratchet clicks when I turned the engine over after installing the left hand cover (twice!) convinced me I was doing something wrong despite following the manual. On examining the kick starer ratchet pawl I finally realized that it needed to be turned one full rotation to lock it. Voila! It works! Since I could not find a topic on installing the kick starter I thought I would describe the process so that neophytes like me would be spared the pain.

First, insert the spring anchor pin into its bore in the crankcase. Now, assemble the kick starter mechanism: Slide the kick starter lever (you will need this later) onto its splines on the kick starter shaft (#1 in Fig.95 on page 57 of the Blue Manual). Slide the outer cup/collar (#2) and insert the kinked tang of the spring (#3) into its hole in the shaft. Then slide on the inner cup/collar, and the ratchet pawl (#5) onto its splines on the kick starter shaft. The ratchet pawl should be fitted so that the right most edge (looking at it from the side of the kick starter lever) is approximately 34mm from the outer curve of the spring with the spring (Fig.96). I tensioned and relaxed the spring several times to make sure it was not binding anywhere when I took this measurement. I also marked the pawl and an adjacent spline with a red marker (I got tired of remeasuring each time my tired hands slipped and the springs boinged their merry way across the shop). Holding the whole assembly in tension, slide on the kick starter gear pinion (#6) - it rotates freely on the kick starter shaft.

Still holding it in tension, slip the whole assembly into the case, first making sure the hook of the spring is around the previously installed spring anchor pin, then sliding the kick starter assembly into its bore in the crankcase, with gear pinion (#6) mating with the corresponding teeth of the large gear. Now comes the trick: hold the assembly in place and in tension with your left hand. With your right hand, swing the kick starter lever a full turn to the right. As the lever reaches the ground, you will see/feel/hear the ratchet pawl ramp lock onto the taper of the spring anchor pin.That's it - it is locked and it won't spring loose. Somehow, this last vital line is missing from the manual. This is most probably old hat to you Morini veterans out there but it took me around 8 hours to figure this out! Now remove the kick starter gear and finish putting on the left hand cover and clutch.

After the left hand case is installed, slide the kick starter halfway onto its splines so that approximately half the width of the lever pivot is aligned with the end of the crankcase boss or 15 to 18mm (Fig 98/99). Depress the lever untill it clears the crankcase boss/kick starter lever stop and then push the lever fully onto its splines and tighten. When released, the kick starter should hit the crankcase to stop.

Hope this helps.

[Chips1953]

I looked this up on the site as I was having the same problem. Full marks and thanks.
I just had a look at Pauls excellent Youtube video of fitting the mechanism. I'll try it tomorrow. looks so easy.

[Chips1953]

I just had a look at Pauls excellent Youtube video of fitting the mechanism. I'll try it tomorrow. looks so easy.

Well there you go, it slotted in 1st go, Thanks Paul.
I must just say that being a member of the Riders Club is worth it's weight in lack of frustration. Value for money all the way. Cheers.