Kickstart shaft kit

[kennystag]

Hi all,
I have just fitted a kick start shaft, piston and springs kit to my GP. I am having a bit of a problem fitting the chain cover, the piston shaft is hitting something inside the case, is there a position that the shaft goes
for the teeth in the piston to mesh with first gear.
Cheers
Stag

[Wack]

If it has a GP endplate, when you fit the casing and tighten down it pushes the piston pin to make the piston teeth clear the 1st gear teeth.

[Scooter Paul]

With a GP set up I always turn the kickstart shaft clockwise with a set of pipe grips as I fit the side case. This allows the plunger to clear properly and engage with the endplate.
I wrap the jaws of the pipe grips with duct tape to soften the grip on the splines to ensure no damage is caused.
Paul

[kennystag]

H,
I have tried to set the shaft onto the ramp then on with the casing , then the engine will not turn as there seems to be a jam inside the case. This thing is driving to go back on the drink can you have a look and tell me what goes where. Feel like a right idiot lol
Cheers
Stag

[dave81]

I have been overhauling my SIL GP over the winter. When I drained the oil out of the gearbox it appeared black even though I changed it when I got the scooter and have only done a couple of hundred miles at the most over 2 years. When I removed the side casing the end of the gearbox shaft looked like it had been rubbing on the clutch top plate. I have not got to the stage of refitting the side cover yet. Is this happening in your case as well or am I looking for a different answer in my case.

[HxPaul]

[quote="kennystag"]H,
I have tried to set the shaft onto the ramp then on with the casing , then the engine will not turn as there seems to be a jam inside the case. This thing is driving to go back on the drink can you have a look and tell me what goes where. Feel like a right idiot lol
Cheers
Stag[/quote
Put the kickstart lever on (it doesn't need fastening)and turn it clockwise about a 1/4 to a 1/3rd of a turn as your feeding the case on.

[kennystag]

Paul.
I have tried as you said and it still does not want to work the way it should, and sometimes it jams as the kick start will not turn the engine.
Cheers
Stag

[HxPaul]

When you look at the kickstart shaft in the picture,if you imagine that it points to 1or 2 0-clock,it needs to point between 10 and 11 o-clock,before you try and fit the cover.

[kennystag]

I just jams, getting really fooked of with it now. I am going to try one more time, if it is not right it is going in the skip at the end of my road.

[dave81]

I'm no expert as my post on this problem shows but have you tried fitting the casing without the kickstart spring fitted? You will be able to fit it without any tension on the shaft and may help you turn the shaft to see the position required. Just a thought.

[HxPaul]

Is the shaft completely in the side case bush.If its not seated right into the bush the sidecase wont go on.Check that the bush is fitted flush with the case,if it isn't the shaft wont fit flush with the case and the sidecase wont fit.

[kennystag]

Shaft is right through the seal if that is what you mean, shim fitted with circlip.

[kennystag]

Thanks for your reply Dave.
Cheers
Stag

[coaster]

Kenny, is the piston free to move inside the shaft? just wondering if it's jamming. Maybe remove those washers I mentioned

Colin

[kennystag]

Colin the Piston moves ok, I tried taking out the washers it is just the same, when I put the case back on the engine jams up, it must ne something to do with the position of the pin riding on the ramp, I think it is far to far clockwise and not sitting on the ramp. looking at the case and piston pin where should they go to on the ramp .
Cheers
Stag

[Warkton Tornado No.1]

The World & His Wife make so many suggestions….

We’re all trying to help, Mate!

Would you like to try taking the ratchet pawl, pin & spring out entirely, then reassemble to see if the ‘clash’ was with them?

If the kick-start then functions (obviously the pawl is not in place to engage with first gear) you know your problem is with the bits you took off.

If it still graunches, then suspect the inner kick-start shaft face on the clutch.

If it’s neither of those, get back on the drink & I’ll send you a kick-start shaft to borrow, if you like.

The World loves a trier!

[kennystag]

Hi Tornado thanks,
I like your style. I do relies that people are trying to helps and I appreciate that. I will do as you suggest tomorrow .
Cheers Mate
Stag

[coaster]

Mr Tornado has a point there Kenny, not all shafts are made to the tolerances originally intended, I have had to remove an obscene amount from one I fitted with an angle grinder in order for it to clear the clutch bell

[kennystag]

Hi All,
Morning headlines. Lambretta is saved from the skip. Stag from the Isle of Skye has saved a classic lambretta from going to the skip, because of the trouble he had in doing a simple fooking job, but he showed determination, and worked into the wee small hours, and sorted the simple job, that nearly caused the end of the line for this fooking Lambretta. But he did show heart and saved this Lambretta, and stuck his wife in the skip instead, well nearly.
Cheers
Stag

PS
The spring was the problem

[kennystag]

It was the main tension spring for the shaft that was the problem, so I tossed it and used the old one sorted. now waiting on a new kickstart coming.
Stag