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AJS 250 lightweight kickstart
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stubaker58
Sunny Felixstowe
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November 6, 2018 - 9:31 pm
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Knowing the depth of knowledge and experience represented on this forum I’m hoping someone can help me out.

As well as my Bantams I’m also the proud owner of an AJS model 14 CSR.  The trouble is that, like Bantams, the kickstart lever splines wear and mine are now non existent. Unlike Bantams however new levers are not available, I did fine a straight lever which fits on the spindle but, as it is not cranked like the original, hits the silencer.

Any thoughts about how to overcome the lack of splines on the lever?  

Anyone got a replacement lever?

is it possible to buy the straight lever,cut the splines section off it and weld the cranked section of my old lever on?

Thanks for your thoughts.

D7/14 hybrid (4 speed with D7 crank etc.) on the road, D10 Bushman awaiting rebuilding.

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dienelt1
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November 6, 2018 - 10:16 pm
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If you don't mind  messing the chrome up you can get someone with  oxyacetylene  equipment .

to fashion it to the shape you require, could make a rough drawing. 

did one for  a RE 250 no probs,  nearly always a bodge possible.

  Diene.

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mike p5xbx
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November 6, 2018 - 11:25 pm
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I Thought the kickstart on the CSR was fairly straight new, is it just the end hitting the silencer
but if not have you seen this
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D? - D10- D14 Bantams 350 AJS -500 Triumph http://bsanotru.....lfire.com/

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stubaker58
Sunny Felixstowe
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November 7, 2018 - 7:09 am
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Thanks for the ideas. 

The Feked one won’t fit, the trouble with the AJS/Matchless lightweights is they have a unique gearbox, and the kickstart spindle is only around 5/8ths diameter with very fine splines.

I did wonder about the other lightweight ranges in the AMC stable, could there be some rationalisation of parts? eg James?

D7/14 hybrid (4 speed with D7 crank etc.) on the road, D10 Bushman awaiting rebuilding.

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Mags 1
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November 7, 2018 - 12:22 pm
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5/8ths sounds very close to many small Japanese lightweights I think, have you tried taking the male splined part to shows jumbles etc and try it out on some of those? Maybe a chance.

Four now on the road and at least several in bits.

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stubaker58
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November 7, 2018 - 4:07 pm
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We obviously think alike Mags.  I’ve tried a CG 125 lever, the diameter is ok but the splines are coarser.  I’ll keep looking!

D7/14 hybrid (4 speed with D7 crank etc.) on the road, D10 Bushman awaiting rebuilding.

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johnsullivan
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November 10, 2018 - 9:31 am
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 Indeed have a look at the forgotten members of the AMC family .FB /James . and Villiers too. I think the Norton Jubille had the fine splines .Reshaping the lever is not too daunting if you have a farrier or blacksmith handy they will find this easy ,for an 'amateur' envisaging where to apply the bend is often hard.

67 D10. and a D7    2007 Honda Hornet FA. Suzuki 89  DR 250S, Sinnis SC 125. 78 Honda 90  75 Montesa Cota 247 an electric scooter of famous make.

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stubaker58
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November 10, 2018 - 9:38 am
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I spoke to Steve at Villiers and he explained that the splines on the Villiers will not mesh properly.  The AMC two strokes seem to be compatible and also the Jubilee/Navigator.  Problem there is that their kickstarts are just as unobtainable!

I’ve bought one of the straight ones, which I know fits the splines, and I’ll get someone local to bend it.

Regards

D7/14 hybrid (4 speed with D7 crank etc.) on the road, D10 Bushman awaiting rebuilding.

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