gearbox/kickstart woes! :-(

[ridden not hidden]

Ok so last week kickstarted my TS1 and felt something give but didn't think to much of it (20+ years of lambrettas should have told me not to proceed) but I popped to the shops came home and put it away. This morning I open up the casing and its carnage!, the kickstart shaft piston circlip and spring are sitting in the bottom of the casing nestled amongst a pile of debris that used to be part of the 1st gear kickstart teeth!. Now I understand that a full strip and check/replace of all components is required and will be done but I wanted to seek opinions on the following:
My current gearbox is AF close ratio, do they still sell them and if so can I just get 1st gear?

I have read that the AF box in high BHP motors can be weak so is it worth going for something else anyway and if so what do people recommend?

what do you think caused the circlip and spring to give way and can it be avoided in the future?

It currently has the GP ramp but I have heard its better to convert to LI/SX type for more leverage, is this worth doing?

[Doom Patrol]

I should say so. People seem to prefer it because you can adjust the ramp. And it seems relatively easy to do for those with a bit of technical savvy.

[10 inch Terror]

Yes is the answer. It's very easy to do and once you've done your 1st one you'll never look back.




All you need is a drill, 5.5mm drill bit and a decent 6mm metric tap. It's one of the most worthwhile modifications to do in my opinion.

[ridden not hidden]

Thanks for the pics looks simple enough, do I need to change to an LI type endplate?

[10 inch Terror]

You just cut the ramp off the end plate you already have. It should be machined for the casing you're using.

[DaveTomo]

Thanks for the pics looks simple enough, do I need to change to an LI type endplate?

As said above just cut the ramp off - much better adjustment also takes the pressure of the kickstart off the endplate

[ridden not hidden]

Thanks chaps definitely going to do this mod. I have a concern about the kickstart shaft that I am using because the circlip and washer have obviously let go along with the spring. do you think this is likely to happen again or should I replace the shaft?

[alanscottj]

To answer 2 of your other questions, yes, AF still make the close ratio, and yes you can buy a first gear on its own. I have just fitted the AF close ratio to my TS1

Also, I have just converted the kickstart ramp on mine, the difference on the kickstart is amazing. For the first time since owning this engine, the kickstart connects straight away, it used to travel abut 2-3 inches before it connected!

[10 inch Terror]

http://www.lambrettaspares.com/spares/k ... 20scl.html

If you haven't already, fit one of these circlips.

[ridden not hidden]

To answer 2 of your other questions, yes, AF still make the close ratio, and yes you can buy a first gear on its own. I have just fitted the AF close ratio to my TS1

Also, I have just converted the kickstart ramp on mine, the difference on the kickstart is amazing. For the first time since owning this engine, the kickstart connects straight away, it used to travel abut 2-3 inches before it connected!

That's good news on both counts