Kick start hitting gear

[prog54]

Using a GP end plate with integral ramp but kickstart shaft piston is hitting slightly on first gear teeth when in neutral, once clutch engaged clicking stops.
To adjust kickstart onto next spline of shaft only allows about 3" of kick before hitting floor.
Any ideas please.

[bazza3004]

Is the bush in the sidecase seated correctly as if not the shaft will protrude into the case too much . May just need pressing through alittle then a shim and circlip (the ones with the tabs on to spread load are best.) Failng that try a thicker sidecase gasket.

[Knowledge]

Any ideas please.

Terry,

This is why a lot of people prefer the Li endplate with the ramp mounted inside the side casing. The GP endplate with the fixed ramp offers no room for adjustment. A double gasket maybe the simplest answer, though the clutch cable may need a tweek afterwards.

[Wack]

Try removing the kickstart pedal buffer in the casing, if the clicking stops cut a bit off the buffer and refit.

[prog54]

Thanks guys all very helpful and will try these out but I don't understand why it stops when the clutch is pulled in as I can't see why doing this would alter the distance between the kickstart piston and the gear cluster.

[Wack]

Pulling the clutch in disconnects the cluster from turning thus not turning the gearbox.

[prog54]

Thanks very much understand now. cheers

[rossclark]

Is it a new shaft?

I had one with the splines machined wrong, came in fake SIL packaging from an auction site and not a particularly cheap one either.

[holty]

hi, a good upgrade is to fit the non gp ramp onto your crancase cover, if its not already drilled and tapped there are 3 dimples showing you where to drill then tap, then remove your gp gearbox end cover and replace with a non gp version, or simply cut it off, i did this to mine as i couldnt get a proper adjustment with the kickstart, it was either too low and i couldnt get enough kick to start the engine, or too high, it seemed like a combination of splines in the kickstart not right, and splines on the shaft not right. once the ramp was fitted to the outer case i was able to adjust it until i only moved the kickstat a short distance and it engaged, quite a lot of messing around, but end result an easy to start scooter, also no ramp on the gearbox endplate is kind to the endplate, less strain, ive already bought another ramp to convert my nxt project,
holty

[holty]

i meant to add, my kickstart rubbed on the top clutch plate as well, a little light work with the grinder soon made a bit of clearance, do check your kickstart shaft is all the way in first,shimming it helps to keep it all the way in,as recomended above, also check your pin on the end of the shaft for wear.

[prog54]

Cheers guys. Not my scooter so I will try the easy methods first before suggesting end plate changes.