Banshee23! Posted July 23, 2009 Report Posted July 23, 2009 How much play should there be if any in the kick gear and kick idle gear? In the attachment, the gears are #2 and #8. I had a rattle at idle and was trying to find what it may be. It doesn't happen all the time. I already checked the flywheel and everything appears to be tight on that side. I have pulled the clutch side cover off and noticed both of these gears have play. Thanks. Quote
Banshee23! Posted July 23, 2009 Author Report Posted July 23, 2009 headed off to ride tomorrow up north, so any help/suggestions would be great. I have to put the bike back together tonight. Quote
XxMeltIcexX Posted July 23, 2009 Report Posted July 23, 2009 The gear has play in it so it can slide out, the gear on the tranny has a little play as well. I think you are hearing your kicker rattle. Need a rebuild kit. Quote
Banshee23! Posted July 23, 2009 Author Report Posted July 23, 2009 so some play is expected? the kicker feels real tight and doesn't rattle. Quote
No Limit Powersports Posted July 23, 2009 Report Posted July 23, 2009 If the idler gear has very much play it will bind up with the kicker gear when it trys to engage. Causing the c-clip to break off and go into the clutches and tranny. I always replace them if they have very much play in them. Quote
Banshee23! Posted July 23, 2009 Author Report Posted July 23, 2009 so do you replace the bushing(steel?) or entire gear Quote
J-Madd Posted July 23, 2009 Report Posted July 23, 2009 Yeah, I'd replace it...or at least get a new bushing for it. I wouldn't let it stop me from riding this weekend, though. I've had those clips come off several times, and only once did it actually damage anything. The one time was a nightmare, though....idler gear came off and bound between the clutch basket and case, then shot the lockup throught the lexan side cover onto the track at the staging lane, then I coasted past the 60 foot mark. Quote
No Limit Powersports Posted July 23, 2009 Report Posted July 23, 2009 You have to replace the entire gear. I usually carry them but im out of them right now. Give Jeff @ Fast a call he might still have some.. Quote
Banshee23! Posted July 23, 2009 Author Report Posted July 23, 2009 I sent email off to Jeff at FAST to see if he had any suggestions and if he has the gear/bushing. Quote
Banshee23! Posted July 29, 2009 Author Report Posted July 29, 2009 Update. I had to take another quad up north last weekend. Put everything back together. Started the shee, idled for about 40 seconds and then I heard a clunk. The shee stalled and now I can't move the kick starter. I'm assuming the idler gear found the kick starter gear and is stuck. At least i wasn't ridding it. I will have to take the clutch cover off and replace the idler gear with a new bushing from FAST. Are you able to remove the clutch without the special tool? Thanks. Quote
Banshee23! Posted July 29, 2009 Author Report Posted July 29, 2009 also, in the picture at the top of the post. what is item #6? it is labeled a stop, but I don't remember seeing it when I had the clutch cover off. I don't see it on any pictures on ebay of the assembly either. Quote
locogato11283 Posted July 29, 2009 Report Posted July 29, 2009 If the idler gear has very much play it will bind up with the kicker gear when it trys to engage. Causing the c-clip to break off and go into the clutches and tranny. I always replace them if they have very much play in them. word.. you should replace the bushing, washer and clip all at the same time. ive had the clip come off, but somehow the gear stayed on. lucky i guess. there shouldnt be that much play. Quote
J-Madd Posted July 29, 2009 Report Posted July 29, 2009 also, in the picture at the top of the post. what is item #6? it is labeled a stop, but I don't remember seeing it when I had the clutch cover off. I don't see it on any pictures on ebay of the assembly either. You have the stop. Its in the case and the kick starter spring curves around it. YOu don't need a special tool to take off the clutch. Just an impact wrench and a 32 mm socket. I leave the plates and fibers installed, then you can just press against them with your hand to keep the clutch hub from moving while loosening the nut. Quote
Overboost Posted July 30, 2009 Report Posted July 30, 2009 my kicker broke the retainer right off the inner shaft and just hangs there behind the clutch. all I have is a rattling kicker. no issues with it being that loose. when I had the clutch out, there was no wear, scratching or anything on the gear or clutch, just a snapped retainer and washer which I fished out of the clutch cover. if it goes out one day, gives me an excuse to upgrade..........4MIL...MUWHAHAHAHA (evil mad scientist laugh) Quote
Ieat4strokes Posted July 30, 2009 Report Posted July 30, 2009 I have a noise as well, took of clutch basket and the rivets on back were marred up like something was hitting them....only thing it could be is idler gear im guessing, i can wobble mine back and forth....hmmmmmm, but the noise sounds like its coming from top end! Quote
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