figure8racer7463 Posted September 2, 2009 Report Posted September 2, 2009 OK guys i was riding 3 weeks ago just cruising up a hill in like 2nd gear not pushing it just cruising along. All of a sudden the shee made a wierd noise, not really a knock more of a mix of whirring/grinding. When it started making this noise it immediately lost all power/died and coasted to a stop. I couldnt shift at all and couldnt engage the clutch. The lever had no pressure and just bottomed out. I pulled the cover off out in the field and removed the clutch springs and screws to disengage the clutch/tranny. I thought the pancake bearing had worked its way loose because when I re-adjusted it and reinstalled the springs and screws everything worked as it should at least with the motor not running. I did not continue to ride since i didnt have any tranny fluid with me so we trailered it and took it home. When i got home i pulled the clutch cover and noticed that the idler gear bushing was shot and it was wobbling pretty bad on the shaft so i ordered and new one from Jeff and installed it on the idler gear. A while back my idler gear popped off the shaft and the groove for the clip was damaged so i couldnt re-install it. I had the idler gear welded on the shaft so i could wait till winter to tear it apart since im going to do a compelte rebuild and just wanted to get it through the summer. I had the welding shop weld the outer washer on the shaft up tight against the idler gear and it still spins like it should on the shaft so i dont think it is the problem but im definately not an expert. Since i was in there i installed a billet basket and put it back together. My problem is last night i finally got it all buttoned up and went to kick it over and cant kick it at all. The kick start lever will not go down even an inch. Before i installed the new basket i checked to make sure the kicker gear would engage the idler gear properly and it worked as it should. Once i installed the basket which went on very hard and had to be beat on with a rubber mallet it seemed to cause it to bind up. The big gear on the back of the basket is a little chewed up but not completely trashed and the smaller gear on the back of the basket doesnt look perfect but is in pretty decent shape. I can turn the crank over with a wrench with no problems so i dint think it is a bottom end motor problem (again not an expert could be wrong). What could be the problem? Should i replace the gears? I have an extra set of the big gear and crank gear that are a matched set in perfect shape that i could put on but dont have the smaller gear. Should i get one of those also? My biggest worry is that it is an internal tranny problem but im not sure. I can take em apart and put em back together but dont have enough experience with a banshee to diagnose problems that aren't visually evident. I realize that i probably shouldnt have forced the basket on there but when i spun the crank gear after the basket was installed, the basket and idler gear were spinnig like they should and without an unusual amount of resistance so i figured it was OK. Any advice would be greatly appreciated as i am supposed to race the DS650 this weekend (refrenced in another thread of mie) and dont want to miss the ride. THanks guys! Quote
blowit Posted September 2, 2009 Report Posted September 2, 2009 Sounds like you need to inspect the transmission. It is common to weld 2nd or 3rd to the shafts and you won't be turning it over after that. If you can find neutral and spin the inner clutch hub or axle free as a bird, it should start. If you cannot spin the inner hub when in neutral, you have found your problem. Also make sure your kicker shaft/spring are installed correctly. Brandon Quote
Paul M Posted September 2, 2009 Report Posted September 2, 2009 The Basket should have slid on very easy no hammer should be needed at all ! sound like something could be jammed up I would pull the basket back off and take a look ! also check the kicker gear !!! if you dont find anything try to spin the motor and pull the shifter through the gears and check the tranny ! and no its not hard to split the cases on a banshee. Quote
figure8racer7463 Posted September 2, 2009 Author Report Posted September 2, 2009 Sounds like you need to inspect the transmission. It is common to weld 2nd or 3rd to the shafts and you won't be turning it over after that. If you can find neutral and spin the inner clutch hub or axle free as a bird, it should start. If you cannot spin the inner hub when in neutral, you have found your problem. Also make sure your kicker shaft/spring are installed correctly. Brandon OK when it is in neutral the axle/rear tires will spin free with no problem but still wont kick over. Should i try installing and new kicker assembly all together? Maybe it is engaging the idler gear kinda funky? Quote
figure8racer7463 Posted September 2, 2009 Author Report Posted September 2, 2009 The Basket should have slid on very easy no hammer should be needed at all ! sound like something could be jammed up I would pull the basket back off and take a look ! also check the kicker gear !!! if you dont find anything try to spin the motor and pull the shifter through the gears and check the tranny ! and no its not hard to split the cases on a banshee. Thats what i thought about the basket also. I used to go on easy no problem until the gears started to show wear. I plan on replacing the gears but am on a limited budget so dont want to replace anything that doesnt need it. I did pull the basket and everything besides the gears looks ok but like i said im not good at diagnosing items which arent obvious. It shifted ok last night through 2nd but i didnt try going any further. I will give that a try tonight. I'm not worried about splitting the cases i can get it done but dont want to if i dont have to. THanks! any other advice would be great. Quote
blowit Posted September 2, 2009 Report Posted September 2, 2009 OK when it is in neutral the axle/rear tires will spin free with no problem but still wont kick over. Should i try installing and new kicker assembly all together? Maybe it is engaging the idler gear kinda funky? I would not replace anything that was not a problem right now. I think careful attention to how things are put together will help you find your problem. As others have noted since I missed it, The basket MUST go on smoothly. It is very possible you roasted the bearing on the back of it and it needs to spin free on the trans shaft. Never should have to drive one on with a mallet. There is not too many things to go wrong in there. If the trans is free, that leaves you with the starting and power transfer system. I still do not quite understand your idler issue but I have never had to weld anything to get one to work. Brandon Quote
figure8racer7463 Posted September 2, 2009 Author Report Posted September 2, 2009 I would not replace anything that was not a problem right now. I think careful attention to how things are put together will help you find your problem. As others have noted since I missed it, The basket MUST go on smoothly. It is very possible you roasted the bearing on the back of it and it needs to spin free on the trans shaft. Never should have to drive one on with a mallet. There is not too many things to go wrong in there. If the trans is free, that leaves you with the starting and power transfer system. I still do not quite understand your idler issue but I have never had to weld anything to get one to work. Brandon Yeah maybe i will start with replacing that bearing and the gears just because mine are showing wear and slight damage which i figure could also cause a bind issue. MY problem with the idler gear was that it popped the clip off that holds it on and when it happened it damaged the end of the shaft and the clip will not stay on any more. Rather than split the cases right now to replace the shaft i had the welding shop weld the wahserto the shaft therefore holding the idler gear on till the winter when i will split the cases and plan on a complete rebuild with porting and a few other goodies. I really appreciate the help and will kepp updating on my progress. Quote
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