GP200 gearbox fitted to Li, something's not right?

[alanscottj]

Ok, took side casing off this afternoon, removed the little top that sits on top of the flange plate, the side casing would go on then without being obstructed and the clutch arm now has a little bit of play before it connects with the clutch. Now that the clutch is free, the engine will start and I have managed a little go round the block.

My only concern now is, will the clutch work properly without the little bit being on? The Li push rod

http://www.scooterrestorations.com/prod ... odmain.jpg

[Fux]

You will wear it down real quick.

I would start by looking at cluch shim or endplate is sitting a little tall because of a thick gear shim.

[alanscottj]

You will wear it down real quick.

I would start by looking at cluch shim or endplate is sitting a little tall because of a thick gear shim.

Looks like it's getting taken apart again tomorrow

[HxPaul]

You shouldn't have to remove the thimble on top of the clutch,especially if it was working well before you changed the gearbox.If I were you I'd be looking elsewhere and I'd check the endplate fitment first.

[alanscottj]

You shouldn't have to remove the thimble on top of the clutch,especially if it was working well before you changed the gearbox.If I were you I'd be looking elsewhere and I'd check the endplate fitment first.

The end plate is the original one, the only parts I have changed are the Xmas tree, loose gears and the clutch pressure flange (the original one has the spindle for the hollow Li Xmas tree) I have put the old flange next to the new one and they are the same size so there is no difference there.

[shocky]

You shouldn't have to remove the thimble on top of the clutch,especially if it was working well before you changed the gearbox.If I were you I'd be looking elsewhere and I'd check the endplate fitment first.

The end plate is the original one, the only parts I have changed are the Xmas tree, loose gears and the clutch pressure flange (the original one has the spindle for the hollow Li Xmas tree) I have put the old flange next to the new one and they are the same size so there is no difference there.

How did the first gear shim up to the endplate after you swapped everything over ?

[alanscottj]

It was really, really hard to get the end plate on to be honest, I'm going to take it off again tomorrow to check that it was sitting flush.

[Adam_Winstone]

One way to make this easier is to fit the endplate and start to tighten the nuts, then fit the clutch centre and tighten the clutch centre nut, which pulls the Xmas tree home through the bearing, then remove the clutch centre and tighten down the endplate nuts again. This can help the endplate sit fully home, rather than tighten on the xmas tree.

Good luck.

Adam

[alanscottj]

One way to make this easier is to fit the endplate and start to tighten the nuts, then fit the clutch centre and tighten the clutch centre nut, which pulls the Xmas tree home through the bearing, then remove the clutch centre and tighten down the endplate nuts again. This can help the endplate sit fully home, rather than tighten on the xmas tree.

Good luck.

Adam

Thanks Adam, I'm going to take of the clutch centre nut tomorrow and see if the endnote nuts will tighten down farther, this should ensure the end plate is sitting flush

[alanscottj]

Ok, took her apart again this morning. Found that I had put two shims under the Xmas tree, I hadn't noticed that when the new GP one came in the post there was one already on there! Same colour, a little bit if oil, and it was pretty much invisible. So, that was one thing, next I noticed that the top clutch plate was sitting quite high in the basket, the lugs were well out of the slots, the flange had new marks on it from rubbing on the kickstart shaft. I decided to fit my original flange after cutting off the spindle, the top clutch plate was still a little high and the lugs were slightly above the slots but no way near how they were before. Having consulted Sticky's I did what he suggests and bent down the lugs to ensure they sit in and the plate doesn't spin. Put her back together, side casing fits like a glove (with the little thimble), she started first kick which was very reassuring and I managed a good spin round the town with no issues thanks all for your help, as always, much appreciated