Kickstart return spring

Good evening,
I have been struggling for some time to install a new k/s return spring on a new shaft. The first new spring I tried to install was sourced from Norvil. It was very stiff and I gave up on it. Then I ordered one from AN which appears to be more compliant.
After struggling for one hour I have succeeded bringing it into position. Now, is the short tang suppposed to fit in the small or large hole at the shaft?
Once the short tang is in place, how to I wind (pretension) the spring and bring the hook onto the small protruding cylinder (the anchor)?

Strangely, there seems to be no thread about the proper procedure on this site. Is it that simple? Or so complicated no one has tried it themselves?
This is my first AMC-2 type gearbox assembled from ground up, which may sound a bit strange.

There isn't much help in the service manual (to me at least). Extract from Section D10:



I am no wiser. Your advice based on own experience is gratefully received.

TIA

- Knut

mdt-son said:

Good evening,
I have been struggling for some time to install a new k/s return spring on a new shaft. The first new spring I tried to install was sourced from Norvil. It was very stiff and I gave up on it. Then I ordered one from AN which appears to be more compliant.
After struggling for one hour I have succeeded bringing it into position. Now, is the short tang suppposed to fit in the small or large hole at the shaft?
Once the short tang is in place, how to I wind (pretension) the spring and bring the hook onto the small protruding cylinder (the anchor)?

Strangely, there seems to be no thread about the proper procedure on this site. Is it that simple? Or so complicated no one has tried it themselves?
This is my first AMC-2 type gearbox assembled from ground up, which may sound a bit strange.

There isn't much help in the service manual (to me at least). Extract from Section D10:

View attachment 124314

I am no wiser. Your advice based on own experience is gratefully received.

TIA

- Knut

Click to expand...

Knut...................I'm thinking that you fell into the same trap that I once did.
Check this out. Good luck

What a lot of people miss is removing the nasty sharp edge on the tang that goes in the hole, and when fitting it, it scores the shaft along its length. I always dress the end of the tang with a small slip stone to round the end of the tang so it doesn't ruin the shafts finish. Once in place (tang in the hole) and using a screwdriver or two wind the spring around the shaft to get the end of the spring over the anchor pin. Takes five mins at most.

A big screwdriver a bit blunt from years of use is in my toolbox. You can use the shaft itself for leverage to prise it over and into the shaft hole . I used vice grips once or twice too.

Hi guys, persistence pays off - my k/s spring is finally in place. Lessons learnt:

* Fit the outboard end of the spring in the 9 o'clock hole at the k/s shaft while shaft is in resting position, cf. fig. D6.
* use a plier to push tang fully home,
* the inboard end of the spring now rests against the wall of the inner cover,
* use a spring tensioner tool or a thin cord for pre-tensioning the spring. I used a cord, which was hard on my long finger (the indents will pass!).
* use a screwdriver for levering the spring hook over the anchor pin. An extra pair of hands is useful, but I managed by myself in the end.
* push the spring against the "floor" of the cover and make sure the tang is still properly located.

- Knut

I wish I had thought of de-burring the end of the tang! Here is the tool I used to pull the spring into place. It made quick work of the job.