From:Mark L Hunnibell
Subject:RE: Revisiting Jamming Kickstarter Date:Mon Jun 29 14:45:32 2020
Response to:7355

I do not know if your problem has any relation to mine, but when my 1919 Z2 engine was rebuilt, I had a new kicker flange installed (this is the thing that screws onto the case (mine had 12 screw holes, but I think others have less) and holds the kick lever elbow). The new kicker flange was beautiful.

The PROBLEM was that my new perfect flange did not conform to a "factory fix" that I discovered had been made to the original flange (which I still had and will attach to this post). It seems that the factory had not properly aligned the kicker flange with the shaft inside the engine to which it connected. It seemed that they set the cross-shaft 55 thousandths of an inch deeper than the mount hole. As a result, the two little gear rings just inside the flange (one on the kicker arm and the other on the shaft) were misaligned. They addressed this problem by specially machining a kicker flange whose inside center was 55 thousandths off center from the outside of the flange.

By using a perfectly-centered flange, my "sprag gears" were not engaging straight on. Eventually, one or more teeth on the sprag gearsbroke off and ended up inside the gearbox, damaging at least two gears. $$$$!

What's the point to you? I think it might be worth it for you to look into this as possible cause by unscrewing the kicker flange and removing it (I do not recall if you have to remove the kicker lever first, but it should not be a problem). See if there is any measurable offset of the center of the kicker arm and/or center of the engine-side sprag gear. If there is an offset, check for interference damage on the sprag gear faces. If any teeth are missing, you probably need to crack the case. If there is some damage but no missing teeth, you may be able to address it by putting the flange back on with an offset that aligns with the offset on the bike (it could be you removed it at one point and put it back without realizing it went on only one way to preserve the alignment of the sprag gears.

Good luck,


I mentioned this a few years ago but thought I'd toss it out there again to see if I could get a more definitive answer.

The kick starter on our Streamline occasionally jambs. It returns to the top but upon trying to use it again feels like a pawl or gear has lost synchronization and refuses to engage. This leaves the lever at the top of its stroke moving just about an inch before stopping dead.

Locking the clutch in it's disengaged position, the lever will go through it's full stroke and in any gear, providing the rear wheel is off the ground.

The problem will clear itself with a combination of turning the rear wheel and prodding of the kick starter but I have not noticed any real pattern.

The big question I have is, does anyone know what might be happening and is there any danger in riding the bike?
Having never seen the gearbox/clutch/engine train exposed and only in the factory drawings, I'm having a hard time figuring out exactly where the problem is. I assume it is simply worn components but have been unsuccessful in dealing with it in any external adjustments.

There is an evident weld suggesting that a repair was done at some point. Safe thing to do would be to pull the engine and investigate but as it is not an easy task we're trying to figure out if it is the only reasonable course.


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