7 replies to this topic

[simmsy]

I have just replaced a cracked clutch casing for a friend on his Gas Gas 280 TXT.
Everything looks fine, the springs, washers all are in right position.
The kick start works fine with new case either removed on put on slack. As soon as the bolts are tightened the kick start seizes up.
Pulling my hair out. Any advice welcome.
Cheers.

[simmsy]

simmsy, on 24 January 2012 - 11:00 PM, said:

I have just replaced a cracked clutch casing for a friend on his Gas Gas 280 TXT.
Everything looks fine, the springs, washers all are in right position.
The kick start works fine with new case either removed on put on slack. As soon as the bolts are tightened the kick start seizes up.
Pulling my hair out. Any advice welcome.
Cheers.

Any Ideas???

[zerorev3rev4]

try the old one back on and see if problem still there or try and rotate shaft as you put it on ,sounds like case could be differnt or shaft not seating correct

[lineaway]

The kickstart shaft has popped out a little. It has to be reset in the case. Did you replace a broken shaft also?

Edited by lineaway, 25 January 2012 - 01:10 PM.

[simmsy]

lineaway, on 25 January 2012 - 01:04 PM, said:

The kickstart shaft has popped out a little. It has to be reset in the case. Did you replace a broken shaft also?

Didn't replace the shaft, but I did remove it to insert a new kick start stop.
I have tried to put the shaft in further but it is in a far as it can go.
I will take it out tonight and check that the casing bearing is not restricting it.

Edited by simmsy, 25 January 2012 - 03:50 PM.

[simmsy]

zerorev3rev4, on 25 January 2012 - 09:05 AM, said:

try the old one back on and see if problem still there or try and rotate shaft as you put it on ,sounds like case could be differnt or shaft not seating correct

The old one is in bits cracked badly. Going to check that the shaft is locating all the way into the bearing tonight.
Thanks

[lineaway]

simmsy, on 25 January 2012 - 03:49 PM, said:

Didn't replace the shaft, but I did remove it to insert a new kick start stop.
I have tried to put the shaft in further but it is in a far as it can go.
I will take it out tonight and check that the casing bearing is not restricting it.

It is very easy to get that wrong,tonight I`ll see if I can find the tech bulletin.http://www.trialspartsusa.com/tech.html
It is in the right hand column, about 2/3 of the way down. See JSE post below.

Edited by lineaway, 26 January 2012 - 12:44 PM.

[JSE]

lineaway, on 25 January 2012 - 11:54 PM, said:

It is very easy to get that wrong,tonight I`ll see if I can find the tech bulletin.

If this is a Pro, there is info as to indexing the kickstart under:
GASGAS PRO TECHNICAL INFORMATION
GASGAS Pro Engine Technical Bulletin UPDATED JUNE. 08 2010

If this is not a Pro, but the earlier design (I didn't see it mentioned) there is
info as to how to set up the Kickstart in another part of the Tech section.

There is a very thin washer that goes on the outer end of the shaft (not on the inside)
and it's easily lost when the cover is taken off. A rider could replace it accidently
with another washer that is slightly thicker and this would bind the shaft.

Make sure you use a new GG sidecover gasket as the gasket also acts as a spacer and leaving it
off and thinking sealer will work will result in binding of the shaft.

Jon