Gearbox Woes - Help Needed...!

[steeleyscoot]

Got a weird one so any clues would be gratefully received...

I'm trying to fit a (late) Li 150 Pacemaker gearbox and the 3rd gear cog will not mesh into the corresponding gear on the gear cluster that came with it when I bought it....

I've counted and counted again to make sure I've got the right combination of toothed gear cogs/cluster as the listing in the manual, and I've even measured the diameter of the loose 3rd gear cog (97.2mm) and the measurement across 5 teeth (33.8mm) - all spot on...! All parts I'm using are stamped Innocenti....

Layshaft is straight as a die, in fact I even tried a 3rd gear cog (37 tooth) out of an Italian Li 150 box and it dropped straight in.....

Has anybody got any suggestions please....?

Also can I use the Li 150 3rd gear and if so am I merely looking at a bigger 'gap' between 3rd and 4th as opposed to using a 39 tooth gear as in the Pacemaker box...?

[bristolmod]

assuming you are 100% sure the Christmas tree is correct (11;13;17;19) then the 3rd gear must be wrong......

39 T 3rd gears were fitted to LI125 S1 2 and early 3's and also SX150's; LI125 Specials; 125DL's and GP200's; Whilst the actual 3rd gear was the same part number on GP200; GP150; GP125; LI125 Specials and SX150; it was different on LI125 S1; 2 and early 3; and the Pacemaker.

IMO you need part number 1983 0005

Also be aware that a 39T gear was fitted to TV200 as a 2nd gear under part number 1963 0004

Chris

[tarmac tickler]

i had this problem once,, the third gear you need is the early weak one,, the teeth are wider apart, by that i mean the gap inbetween them is larger hence making them weaker, they break dead easy,, simply fit the li150 37 tooth third cog, from memory they are about a mill smaller,, been running one in my pacemaker for 3 year now with no issues;; it does alter the ratio but its not noticeable

hope this helps