Scooterotica

Hi, i have just fitted a new kickstart lever, but it seems to engage nearer the floor than the one i took off, i even put the old one back on, but this too seems to be doing the same, what have i done wrong.

Wrong position on the kick shaft usually.

you MAY need to reposition the K/S on the actual shaft.

Put the lever one tooth anticlockwise, then gently push down as you tap the K/S in letting the return stop clear the rubber buffer on the crankcase itself- this will allow the mechanism to "take up' any lost motion before it engages.

Make sure that it isn't trying to engage all the time when the engine is running!

Alternatively, and assuming you have the earlier "LI ramp " setup, you can adjust said ramp to engage earlier although this does involve removing the crancase cover.

If you have the later "fixed" combined end plate and ramp then there is no adjustment

Chris

Thanks for your replies, i just can't understand why, when i put the old one back on, in the same position on the shaft, it now acts like the SX lever i put on. The problem with re=positioning the lever is there is not much room to do this,as the stop prevents it. Any suggestions , please.

You turn the pedal one tooth high so that it sits above the stop and then partly pressing the kickstart lever on you turn it down so that it clears the stop before pressing it fully home.

Thanks for your replies, as you said, i just put it on a few teeth back and it's back to normal, unfortunately the new sx 200 k/s, won't line up the same, i'll have to sell it.

Glad you got it sorted. I think some remade kickstarts can have the splines incorrectly machined.

yes kickstarts can have the splines in slightly the wrong position, as can some kickstart shafts and combinations of both, best fix is what i did, and fit an adjustable kickstart ramp into the outer cover, the same as the li has fitted, then cut the ramp off the gearbox end plate, this has a few advantages, less strain on the end plate, and the kickstart will engage very early when adjusted correctly, giving a nice high pedal so you get a long kick to start it up,i also cut the stop rubber down a bit to make the pedal higher, its easy to fit the ramp to the outer case, the 3 pips are already there so its easy to work out where to drill and tap, its an very common and worthwhile upgrade, especially on a high compression engine, or one running a large front sprocket.