Banshee23! Posted August 14, 2009 Report Posted August 14, 2009 Hello all. I had the issue with the kick idler gear rattle. I got that all replaced, but something else appears to be wrong. I put everything back together and I was unable to engage the kick starter. This is the same thing that happened earlier before I replaced the kick idler gear bushing. The kick starter gear was wedged in the kick idler gear. So, I took everything back apart. Spinning the crankshaft nut is not easy. There is a lot of resistance. Should it spin freely? I took both spark plugs out prior to spinning the crankshaft nut. Rough estimate to fix? Should I part the beast out? Thanks in advance. Quote
2strokecook Posted August 14, 2009 Report Posted August 14, 2009 (edited) Hello all. I had the issue with the kick idler gear rattle. I got that all replaced, but something else appears to be wrong. I put everything back together and I was unable to engage the kick starter. This is the same thing that happened earlier before I replaced the kick idler gear bushing. The kick starter gear was wedged in the kick idler gear. So, I took everything back apart. Spinning the crankshaft nut is not easy. There is a lot of resistance. Should it spin freely? I took both spark plugs out prior to spinning the crankshaft nut. Rough estimate to fix? Should I part the beast out? Thanks in advance. I don't know what "not easy" is but by hand with no leverage it my seem hard, ya have to think there is pressure from the seals, friction from each piston and so on, so it depends what you mean by "easy", if the kick starter is not engaging it sounds like you most likly don't have kick starter gear and spring setup put incorrectly, they can be trickly if ya haven messed with it before. But no don't part it out, spend some time and take pride in fixing it your self and ride the balls off of it. Good luck :biggrin: Edited August 14, 2009 by 2strokecook Quote
Banshee23! Posted August 14, 2009 Author Report Posted August 14, 2009 I put a wrench/socket on the crankshaft nut and it was difficult to spin. Quote
2strokecook Posted August 14, 2009 Report Posted August 14, 2009 I put a wrench/socket on the crankshaft nut and it was difficult to spin. do you have your clutch basket off as well, if not make sure your not in gear or something silly. if you are turning just the crank and it is still difficult have you pulled the head and look at the condition of your cylinder walls and such? whats the story behind the motor? noises or anything? Quote
Banshee23! Posted August 14, 2009 Author Report Posted August 14, 2009 Clutch basket is off. The bike was not in gear. I have not taken the head off yet. I had a rattle noise on the bike. Guys from the forum suggested I look at the flywheel and kick idler gear. The flywheel was tight. The kick idler gear had some play in it. I didn't have the bushing to replace the kick idler gear, so I put it back together to go riding. I started the quad up and just let it idle. The rattle noise was there. Quad idled for about 15 seconds and then just stopped. I was unable to kick start the quad. I took everything back apart and the kick starter gear was wedged in the kick idler gear. I wiggled the kick idler gear and it freed everything up. I order a new bushing from Jeff at FAST Racing. I was putting everything back together last night. I couldn't get the kick starter to move again after the clutch cover was bolted back on. The rattle was not consistent before I took it apart the first time. Sometimes it would rattle and sometimes it wouldn't. Quote
figure8racer7463 Posted August 14, 2009 Report Posted August 14, 2009 I think it may be possible that the idler gear is binding with the gear on the back of the clutch basket. I am going through the exact same problem with mine right now without the rattle. When i start to tighten down the clutch basket it wont kick over any more. Make sure the teath on bothe idler gear and gear on back of the basket arent damaged or binding somehow. When i get my parts and get mine fixed i will let you know what i did to fix it. I may be way off base on this also, im not an expert but that was the only thing i could think of that would be causing it. Quote
Banshee23! Posted August 14, 2009 Author Report Posted August 14, 2009 I am hoping the idler gear is fixed with the new bushing, but now I am concerned with how hard the crankshaft seems to spin. Quote
figure8racer7463 Posted August 14, 2009 Report Posted August 14, 2009 I didnt realize that you hadnt replaced the idler gear bearing yet. Yeah that is most likely going to clear it all up. Dont worry about your crank right now. Take one roblem at a time. Probably nithing. Mine is hard to turn also. Gotta remember without it running your cylinders are not being lubed and could make it harder to turn also. Quote
Banshee23! Posted August 14, 2009 Author Report Posted August 14, 2009 I actually replaced the bushing last night. I had everything back together and went to move the kick starter with my hand. It didn't move very far. I tried a little with my foot and it still didn't want to go. It seems like it was binding with the kick idler gear. I took everything apart and started looking at the crank. Quote
VegasJeff Posted August 14, 2009 Report Posted August 14, 2009 I actually replaced the bushing last night. I had everything back together and went to move the kick starter with my hand. It didn't move very far. I tried a little with my foot and it still didn't want to go. It seems like it was binding with the kick idler gear. I took everything apart and started looking at the crank.what did ya find in there? Quote
Banshee23! Posted August 17, 2009 Author Report Posted August 17, 2009 everything looks good inside. Jeff from FAST says there should be some resistance when turning the crankshaft. I want to test compression now. Quote
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