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Kick-start lever dismantle

Submitted by neil_renwick on Mon, 22/02/2016
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Nortons - General

Hi all,

I require help/guidance with the dismantling of the kick-start lever prior to it being re-chromed. I cannot remove the peg which is normally held in place with a nut but on this one, it has a cover and what looks like a circlip below the cover. I have attached a photo of the kick-start peg and cover.

Has anyone managed to dismantle one of these before? I have tried to force the cap off as well as push the cover down in an attempt to further expose the circlip but neither worked. I could revert to brute force but this may render the kick-start swivel action passed redemption.

Many thanks in advance for any guidance/advice to tackle this problem.

Attachments kickstart-jpg

Submitted by gordon_johnston on Mon, 22/02/2016

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It might just be easier to buy a new one. By the time you have prepared it for chroming - no quick task - and had it chromed properly, you have to ask yourself is it worth it when replacements are readily available.

Submitted by richard_payne on Mon, 22/02/2016

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In the old NOC 'Commando Service Notes', there was the suggestion that these levers with a cap (although they speak of a roll pin retainer) were pattern items.

What is it fitted to ?

Submitted by les_howard on Tue, 23/02/2016

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Here is how it might work....don't know if it does work like this but it's aneat method anyway.

The dark metal ring looks, as you say, a sprung circlip type washer. Ifit is, there should be a gap at some point on it's circumference. If it is, you should be able to leverthis sideways and out. The chrome washer above will then drop down slightly and by also pressing the lever down against the bottom spring to increase the drop, you might expose a pin through the previously hidden shank of the domed top piece. Once exposed you can then push the pin out to release the domed top.

If this is not how it works maybe the dome piece is simply screwed on so you might be able to hold it in a vice and rotate the kick-start to unscrew it...(or use Mole grips). Obviously a new dome will be required but a new SS domed nut will be easy to find....or make one and have it chromed with the rest of it.....Les

Submitted by neil_renwick on Tue, 23/02/2016

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Previously richard_payne wrote:

In the old NOC 'Commando Service Notes', there was the suggestion that these levers with a cap (although they speak of a roll pin retainer) were pattern items.

What is it fitted to ?

Richard, the kickstart is fitted to a 750 roadster (reg. 1972) and this has been on the bike prior to 1976 when I acquired it. I agree that it's a pattern item and was more than likely fitted when the previous own changed the silencers from peashoots to blackcaps which then caused issues with footrest and kickstart hitting the silencer. As part of my renovation l,m moving back to peashoots and I would like to avoid additional cost of a new kickstart if I can.

Submitted by steve_constable on Tue, 23/02/2016

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Hi Neil,

For what it's worth my vote is go for a new one.

I had a similar problem and bought a new kickstart lever on eBay for £35.

It looks good and seems ok, and I have done at least a years worth of kicking getting my 72 750 into decent running order.

I guess the question is how much to rechrome and is your old one perfect, without the usual twisting and deformation of the mating surfaces.

I would be interested to know what rechroming costs anyway.

cheers

Steve

Submitted by neil_renwick on Wed, 02/03/2016

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Previously steve_constable wrote:

Hi Neil,

For what it's worth my vote is go for a new one.

I had a similar problem and bought a new kickstart lever on eBay for £35.

It looks good and seems ok, and I have done at least a years worth of kicking getting my 72 750 into decent running order.

I guess the question is how much to rechrome and is your old one perfect, without the usual twisting and deformation of the mating surfaces.

I would be interested to know what rechroming costs anyway.

cheers

Steve

--------------------------

Steve, the cost to re-chrome the kick-start from one supplier was quoted at £50. A quote from a second supplier was for re-chroming the kickstart, gear lever, footrests, brake lever, front mudguard stay and 2 x indicator stems was £175.

Both suppliers use the same processes e.g. copper, nickel then chrome but the lead time for the one I'm using is around 5-6 weeks as opposed to 4 weeks. Both have good reputations but the first is a much larger company whilst the one I've gone with has only 2 people and all their works comes very recommendation.

The cost of both chroming and powder costing can be quite expensive and a number of times I've found it cheaper to buy new as opposed to re-chrome or powder coat but always worth looking at the options.

Hope this helps

Neil

 


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