KICKSTART PISTON CLIPPING FIRST GEAR

[20QL]

After an engine rebuild of my GP200 engine I am now finding that my kickstart piston is clipping first gear when riding, and cannot roll back when clutch is pulled in when I stop as it is engaging with the first gear.

I have changed the indian endplate for an italian endplate and fitted a new kickstart piston and stud and this has not solved the problem?

The scoot is lovely to ride apart from this issue, which I want to sort before IOW!

Can anyone help please?

[jason frost]

Move it round one teeth on the shaft or do this http://www.facebook.com/media/set/?set= ... 888&type=3

[FREAK]

1 change the end plate back there matched to the case
2 elongate the hole the piston pin fits in so the piston teeth are further back than the end of the shaft when fully pulled back
3 shim the shaft coprrectly
4 if that dont work get a innocenti kickstart shaft
5 possibly the side case needs machiening (was a dealer recall in the 60 i bielive)
quite a simple fix just loads of fiddling

[20QL]

Cheers for info. I think i will fit an li/sx piston ramp to side casing.

thanks

[dapper]

First thing I'd check is that the outer kickstart shim is thick enough to ensure the kickstart piston mech is pulled out as far from the endplate as possible, which is a simple fix from the outside without removing the chaincase. and I'd make sure it was one of the new tagged circlips. Then I'd look at the options above. Oh, and I'd check the reference pin that sticks out the side of the kickstart piston isn't worn and the flat end is sitting in the endplate ramp the correct way. Make sure it has a spot of Loctite on it too.

[20QL]

Have checked these items but all ok, thanks again