trouble selecting first...

[byron]

This is on a bought complete Indian GP200 engine in a seriesII.
When first starting up the scooter it goes into gear fine, but after having gone up through the gears and then back down, to stop at lights for instance, it is a real pain to get into first...

Already replaced and checked cables & routing and had the handlebar gearchange apart.
So this week I stripped the gearbox, there was far too much float at the endplate [even with the 2.8mm shim that was fitted], half the endplate studs were loose, the shims & needle bearings were poor quality; so i replaced all the bearings [including a quality rear bearing] & shims, got 0.2mm clearance on the endplate with a 2.0mm shim, put it all back together, but it's still hard to select first after coming down through the gears.... it generally needed a bit of rolling and a rev to get things moving in there...

Anyone experienced anything similar ??
All of the components in the gearbox are recent Indian. The owner has still got the original Li125 engine. I'm thinking robbing parts from that...?
Once in gear, it's fine, it's just getting there, so maybe use the layshaft, sliding dog, selector shaft & arm, maybe even the tie-rod and other external linkages too... worth a go ?
I've done the same job loads of times before without this problem, so don't think I've missed a trick, but any advice welcome.
cheers

[johnny diamond]

are you using rubber gaitors on the cable ends....if so check they are not the cheap tacky semi hard ones

[byron]

are you using rubber gaitors on the cable ends....if so check they are not the cheap tacky semi hard ones

cheers, but I have already got rid of them. I have stripped the old engine and got some nice Italian parts to fit to the Indian lump.
fingers crossed it works...

[Bilko]

Byron, far be it for me to offer advice (a complete numpty). but is there any chance of it being a selector arm issue and it being in the wrong place?

Could the bolt inside be catching or stopping it from getting position?

Sorry if I'm way off or I've wasted your time.

[rog60]

Had a similar problem with my SIL 200 motor. I lived with it then when I changed the clutch plates from(I presume Indian) to 'Surflex type' everything was OK.

[byron]

Byron, far be it for me to offer advice ...

not at all, any advice & tips are always most welcome. I fitted the selector arm as I always do [right angles to casing in 2nd] and haven't had this before. I checked the bolt head cleared before final assembly.
I shall replace the layshaft, sliding dog, wishbone, selector shaft & lever with the bits I just robbed from the original engine.
I posted the same query on LCGB and somebody had had exactly the same problem with a new Indian GP200 lump, and only cured it by replacing bits with innocenti items. so I'm hopeful...

[lamblast]

had the same problem built a gp125 engine then sold scoot then the guy wanted it converting to a 200 so popped it into a 200 casing the only thinge that was changed was the gearbox endplate for the sil one which came with the casing after this build it was hard to get it into first sometimes you had to let it roll back at lights a bit to let it go in .i also know of someone else who had the same problem with a sil engine.when i speak to the guy again i will see if its still doing it or bedded in if it hasnt i will be changing the endplate for him to see if this cures it.

[byron]

had the same problem...

that's interesting, I have got another unused SIL endplate that i was going to try if i couldn't shim it within tolerance [when i first took it apart, it had loads of float on the endplate and already had a 2.8mm shim fitted...]. but had to use a 2.0mm shim in the end, i figured changing all of the the gearbox bearings made this difference.
otherwise, where are we ? the casing is cast out of line...?
should know on wednesday...