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AJS/Matchless Lightweight Gearbox Overhaul

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AJS/Matchless Lightweight Gearbox Overhaul, Reassemble the kickstart mechanism: crwdns2935265:00crwdnd2935265:01crwdnd2935265:03crwdne2935265:0 AJS/Matchless Lightweight Gearbox Overhaul, Reassemble the kickstart mechanism: crwdns2935265:00crwdnd2935265:02crwdnd2935265:03crwdne2935265:0 AJS/Matchless Lightweight Gearbox Overhaul, Reassemble the kickstart mechanism: crwdns2935265:00crwdnd2935265:03crwdnd2935265:03crwdne2935265:0
Reassemble the kickstart mechanism
  • Remove all traces of gasket or sealant from the centre web.

  • Check the kickstart mechanism and bushes for wear and damage, replacing as required.

  • Fit the kickstart return spring using a pair of long-nosed pliers, noting the washer underneath the spring (if fitted). Use a pair of pliers to make sure the spring is fully engaged in the hole in the shaft.

  • Don't forget to fit the coil spring on the gearbox side.

  • Temporarily fit the kickstart and rotate the shaft by hand more than 90 degrees to tension the return spring.

  • Fit the kickstart pawl, then release the kickstart so that the return spring is left tensioned by approx. 90º. It takes a few goes to get it right.

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