Kick start probs

[des]

Last summer I transferred my LI engine internals into a 200 block, all worked well started and drove well

I then left it till recently and found that the kick-start was going to the floor I changed the kick-start plunger for new also put new clutch plates in and it was still going to the floor.

I then changed the Li 1st gear for a GP 1st gear (same no. of teeth) still no joy.

I tipped bike over abit and found the kick-start engages after travelling practically to the floor.

I then moved the kick-start up a few notches on the spline and it started to engage properly, when started it sounded like the plunger was rubbing of the first gear and when stopping the engine there was a big clunk from kick-start /gear box.

I thought this might be down to the fact the GP 1st gear is a smaller dia than the Li 1st gear so I went to put the Li 1st gear back on but found that the end plate would not slot back into place on the layshaft and the gear xmas tree, it was slightly off where the layshaft slots into the needle bearing on the endplate.

If I remove the 1st gear the endplate slots in perfectly, but no way would they line up with the Li gear on, so I ended putting back on the GP 1st gear and back to the same problem of the plunger rubbing and the clunking when cutting the engine.

Any ideas on how to sort this i have wasted hours trying to fix this and cant understand why the Li 1st gear wont fit back its all orginal Li gearing.

Sorry for the lenght of the post and hopefully it will make sense to someone.

[des]

Can anybody confirm if its ok to use a GP150 1st gear in place of an LI150 1st gear in a Li gear box, both have the same number of teeth but the GP cog is a smaller diameter.

[bristolmod]

No- it won't work and could cause a lot of damage..............

don't be tempted

Chris

[bristolmod]

just read you post properly

Looks like some damage has been caused (big clunk etc)

Suggest a full strip down and rebuild using correct gears. The fact that the end plate now won't fit is worrying somewhat. End plate bearing gone?
Layshaft bearing shot? Bent layshaft?? (rare but....)

Chris