5 speed fouling kickstart

[sydduckett]

Anyone else have this issue. I know its covered but any extra info by anybody who has had to grind out the side casing would be good.

Ta
Sef

[Adam_Winstone]

^... probably just about everyone has had to review their assembly when fitting the 5-speed as the design uses all space available. Whereas a 4 speed can be more or less just chucked in, and all will still work, the 5-speed requires a lot more attention on the part of the builder. That said, it is worth it in the end.

The issue of 1st rubbing on the kick-start piston's teeth is covered in great detail by Dean in the assembly instructions and/or the 'trouble-shooting' specifics that Dean has available. In the first instance, I'd make sure that you have and read all the info that Dean has and then consider options. There are many ways of addressing the issue that you face but the differences in other standard and aftermarket parts (layshafts, hub bearings, endplates, kick-starts, kick-start pistons, etc, etc) mean that one solution may be more applicable than others. I'd certainly not look to start grinding out anything until you've read what your options are, especially when there are solutions that might be as simple as fitting a 2nd (or thicker) casing gasket.

Make sure that you have read ALL of the info that Dean has available on the issue. He has lots, with detailed feedback from Sticky, myself and others.

Good luck.

Adam

[dave wheeler]

agree with Adam, check your clearances, which I have never had to do before, shim the shaft as tightly as possible, as it was the actual shaft, rather than the plunger, that was fouling not only the first gear but also the clutch top plate, check the ramp position, all of this plus a 3rd (!) chaincase gasket and its all fine now, ive missed too much of this summer waiting on the gearbox to worry about the engineering etiquete of so many gaskets, a proper job can wait till the winter

[sydduckett]

Im going through it all again but the tips and suggestions are all good. Think ill look at the gaskets first although im not that lucky.

Ta

[a.lo.v2]

not looking forward to this stage myself as the made in italy shaft i have was giving clearance issues on the old set up, both the top and bottom of the piston housing, nothing the dremmel and angle grinder couldn,t sort but plenty of shimming issues to deal with before that

[sydduckett]

further inspection has revealed that the kickstart piston is engaging when its in the up position. Iv moved the ramp as far as it will go and the only way i can get the teeth in the piston to remail flush (and not engage) is to have the kickstart loose under the rubber stop as opposed to resting against it as it was with the four speed in. Thats not ideal as it then bottoms out when kicking over. If i notch it up by one spline then it fouls. Ideally i would have one spline between the 2 and it would probably clear. do indian and Italian kickstart shafts have the same number of splines and or in diff sizes? Im not sure what i have but it looks as though its the italian/correct one judging by the pics in the instructions.

I can go for the smaller shim, have the medium one in at the mo but i think that may loose me the matching of the 5th gears.

I think im going to attack it in this order.


Try 2 - 3 gaskets

Try diff kickstart shaft

Try re- shimming

put washers under the ramp to lift it slightly

Grind out the kickstart by a couple of mm

Whilst the final option seems the most extreme, it would solve the issue and also mean id have the 5th gears as spot on as i can get them. Also the cheapest as i have the tool for the job. Id just have to add a shim to the outside to take up the slack.


What do you reckon chaps....



sef

[Timbo]

Why don't you email Dean?

[dave wheeler]

check the reference pin isn't worn, can make quite a difference if it is

[Terrible Taff]

As Dave said, check the reference pin isn't worn, this can make quite a difference if it is!

Some kickstart shafts are not retained well from the outside, AF Rayspeed do a new shim & starred circlip which helps keep the shaft from moving inwards & hence then rubbing the clutch top bevel plate, all though this is usually cured by grinding away the offending area.

Check that when the chaincase is fitted but with the kickstart lever removed the kickstart plunger does not engage, if it does change the kickstart axle as the slot will be machined incorrectly!

Another remedy is to fit the older kickstart return guide if you drill & tap the 3 holes on the cover like the early Italian chaincase covers were, then cut the return ramp off the gearbox endplate!

Some dealers now have on offer thicker chaincase gaskets, try one of these!

[Dimitrios_231]

You can also try another kickstart (if available), hoping for a different spline position.