GP kick start

[Jeff t]

The Kick start on my GP engages really low and doesn't have much travel once it engages, I tried moving on the spline and then I had a noise that sounds like the plunger is catching. It's always been like this but can sometimes make it difficult to start, just checking I am not missing anything but a part from fitting an li version is there any other way of adjusting a GP kick start.
Cheers

[Wack]

On the endplate you will see a flat area just before the slope where the piston pin sits at rest. If you grind this 1/4 " shorter and blend into the slope the kickstart will engage sooner. It can be done in situ by masking everything with rags and tape and a magnet to catch the grindings if using a Dremel.

[Knowledge]

You appear to be suffering with the problems associated with having the ramp (or cam) that deploys the kick start plunger cast into the end plate of the gearbox. The pre-GP system of deployment offers some adjustment and many people, including myself, convert to this system in preference to the GP set-up.

If you don't want to source a new end plate for your gearbox, simply remove the GP ramp with a hacksaw and drill and tap holes for the earlier style ramp into the GP side casing.

There are some useful photos in Sticky's manual.

[Wack]

There's also the problem with dodgy pedals having the splines machined wrong.

[Mag]

Ive seen remade kickstart levers and shafts with the splines in the wrong place leading to this issue. I've also seen the kickstart piston with the hole on the side in the wrong place leading to it still being engaged with the gearbox even when the shaft has returned to the correct position.

[Jeff t]

Thanks all the shaft and kick start are both casa replacements and seem a good fit, I was just making sure there was no other way of adjusting and will consider options once winter sets in.
Cheers

[bazza3004]

Could you put it on the next spline the one were you say it engages at rest and maybe trim some off the rubber in the casing allowing it to sit abit higher and then it might disengage at rest. .

[Mag]

Thanks all the shaft and kick start are both casa replacements and seem a good fit, I was just making sure there was no other way of adjusting and will consider options once winter sets in.
Cheers

What about the plunger? When I fitted my 5 speed the plunger rattled against first gear, but I looked in my spares box and found a new plunger where the hole for the bolt was nearer the teeth so pulled it further back when on the ramp

[Jeff t]

Decided to fit the Li type ramp, all gone well noticed the kick start bush on the chain case inner was damaged so removed and fitted a new one however the kickstart shaft won't go through the new bush. Anyone had a similar issue is just a case of trying another bush or fettle the one that I've fitted.
Cheers

[Wack]

There's two types LI/SX and GP inner bushes. http://www.scooterrestorations.com/lamb ... ush-inner/

[Jeff t]

Thanks I did wonder and rang up the supplier today but they don't open Monday, think it's my mistake not sure I specified which one.
Cheers

[Wack]

The difference between the two bushes is the depth not the internal size which is roughly around 25 mm with the shaft being around 0.2 /0.3 mm smaller.

[eadmr04]

The difference between the two bushes is the depth not the internal size which is roughly around 25 mm with the shaft being around 0.2 /0.3 mm smaller.

So are the kickstart shafts different between the gp and li type? Do you have to use a gp bush with gp shaft and li bush with a li shaft??