Removing kickstart lever

[AndyB57]

Evening all.

I want to remove the kickstart lever so that I can smarten it up a bit. I've consulted the Blue Book, etc but can find no reference to it so can anybody tell me if there's anything to be done other than loosening the pinch bolt? Or will the mechanism unravel like a clock spring let loose if I don't anchor the shaft somehow as I remove the lever??

Thanks!

[72degrees]

The spring wont unwind completely unless you take off the side cover and disturb the mechanism. You will have to rewind it a bit before pushing the lever back in to place though. See drawing from 'the blue book'. Well when the webmaestro resets the board attachment quota!

[julianharty]

My tip is for you to undo the pinch bolt several turns, then gently, firmly, and slowly pull the kickstart towards you by holding it around the pinch bolt area. Once you pull it sufficiently for the inner edge of the pivot to pass the clutch casing it will probably want to turn anticlockwise a bit (about 20-30 degrees), make a note, take a photo, whatever works for you, of where it ends up. Now you can remove the kickstart completely and do whatever you want to do to fettle it. When it's time to refit it, position it so it matches where it ended up once you'd passed the end of the casing when you removed it. As you push it back on (possibly with gentle taps from a non-ferrous hammer) then turn the kickstart lever clockwise sufficiently so it will avoid the edge of the casing (so about 20 - 30 degrees clockwise). Finish pushing/tapping it on and retighten the pinch bolt.

Test it to ensure it can start the bike and hope you don't hear clattering from within when the engine's running. If you do, then try removing it and refitting it slightly clockwise on the splines.

[AndyB57]

That's great, thank you both.

[Carts]

Hi all

Can you please explain the blue book? I am a member of morini club.

Just wondering as wanted to mark sure my kick start is set properly

Cheers

Carts

[72degrees]

Hi all

Can you please explain the blue book? I am a member of morini club.

Just wondering as wanted to mark sure my kick start is set properly

Cheers

Carts

Login to the MRC website members area with your credentials as supplied.
http://www.morini-riders-club.com/theclub/membarea.html
Go to the library section and you will see: 125/250/350/500 service manual ('blue book') and a link to download it as a PDF file.

It is also available elsewhere, but you will find other useful info on the MRC site including a parts manual (< 1979).

I see the board attachment quota has not been tweaked yet so here is a link to the illustration form the 'blue book':
https://www.gilera.org.uk/Morini/Kickstart.jpg

[Carts]

Hi thanks for that,

Sorry I’m not a great communicator on the website, more a casually browsers. Before the lock down I managed to get a local engineer to convert my 350 to a right foot gear change. But have been struggling kicking the bike over as Kickstarter hits the now gear change. Before the kickstart hit the leaver but the leaver was set 1/2 inch higher and the bike would start. Now I’ve bought a spacer for the kickstart so if I shorten the new gear leave all will be good. I just wanted to make sure the previous owner set up the kickstart properly,

Thanks again for your help

Carts

[LoudenSwain]

Hi, anyone dealing with kickstarter issues should watch Paul Comptons video on YouTube. I found that even if I was addressing issues with the kickstarter without removing the side case it gave me more confidence knowing what was going on in there. Recently I did a full overhaul of the mechanism and the video was of great help. https://www.youtube.com/watch?v=QFKGXoyFtb4

[72degrees]

Hi, anyone dealing with kickstarter issues should watch Paul Comptons video on YouTube. I found that even if I was addressing issues with the kickstarter without removing the side case it gave me more confidence knowing what was going on in there. Recently I did a full overhaul of the mechanism and the video was of great help. https://www.youtube.com/watch?v=QFKGXoyFtb4

Indeed. The description in the blue book for the mechanism doesn't really make it clear about the 'winding up'. It certainly made my 'racer' rebuild easier once I reached that point.