Kickstart Lever Walking off

[MattBond]

I've been helping a friend with his 1948 Ariel Square 4 rebuild, currently having the magnetometer rebuilt as it doesn't seem to be putting out a good spark which we think was making it very difficult to start. With it being hard to start it went through a lot of kicks...and the kickstart lever keeps wanting to walk off the spline. He's already filed the slot in the clamp down to ensure the pinch bolt can add tension, but it doesn't seem to really help. Wondering if this group has any tips on how to get this kickstart lever to hold better.

[Chris Sealy]

I had the same problem in the distant past, also on a Burman gearbox. I tried Loctite on the spline, and a couple of spots of braze.
They both worked for a while, but eventually failed. My final solution which is still working years later, was to drill and tap the centre of the splined shaft, and fit a large, thick washer and screw.

[nevhunter]

It's very hard to drill and tap the shaft as It's HARDened. Splines wont clamp either (by design). Spread the GAP and put a shim in. It HAS to be a tight fit originally. Nev

[Roger Gwynn]

Fit a new shaft!

[nevhunter]

And a Kicker that fits tIght. New end welded on? It won't Break IF it's done right. Nev

[JohnnyBeckett]

hi, i didn't mess around trying to fix it i just get a new one from the club or klub spares

[jim.haydock]

Matt, there is an easy solution that I've used on a number of my Ariels. Although the outside of the shafts (Kickstart and gear) are hardened the insides are soft (case hardening?) and are very easy to drill with a standard HSS drill. They even have indents in the centre avoiding the need to centre pop.
Simply use a 5mm drill to a depth of say 15mm, tap to 6mm and use a penny or repair washer with a 6mm set screw loctited for extra security. If you have access to a lathe you could do as I have done and make up an aluminium cap with a indent to fit the diameter of the shaft (photo attached). Problem solved!

[MarkO]

Jim

Very belt and braces - but I do like it. The caps are wonderfully excessive but they look factory. A splendid reminder of Victorian pride and excellence - when they decorated steam pump houses palatially despite virtually nobody seeing them.

[MattBond]

Appreciate all the feedback from the group. I think we'll likely drill and tap the shaft as Chris and Jim have suggested, we're still waiting to get the magnetometer back from being rebuilt.