andyc607 Posted July 8, 2014 Report Share Posted July 8, 2014 Hi, I am a bit of newbie when i comes to fixing trials bikes but very keen to sort it correctly and would really appreciate anyones advice. Gas gas txt 280 pro 2003 model. After kicking the bike over and running it for a short while i noticed i was loosing clutch oil once i put it on side stand and that the bike would not tick over at all, unless the choke was fully on. I noticed that there was a bit of play ( about and half inch or so ) on the kickstart shaft. The kickstart spring had burst the clutch casing. I have removed the clutch plates and housing to look at the idler gear and it is a little chipped and worn around some of the teeth but not too major. So currently i am planning buying a new clutch casing, gasket, and gear idle cog. I am wondering a couple of things..1: will these actions fix the problem ( the last thing i want to do is kick the bike over and burst a new casing. 2: could the slight wear on the gear idle cog be responsible for the friction kickstart spring bursting through the casing? Many thanks in advance for your help. Thanks. Andy Quote Link to comment Share on other sites More sharing options...
lineaway Posted July 8, 2014 Report Share Posted July 8, 2014 What you did not include is a picture of the kick start shaft and pawl gear. This was very common on 02-04 models. There is a new shaft and gear upgrade that is not cheap. Also check the blind bearing in the case. You can get to it from behind the carb more or less. Quote Link to comment Share on other sites More sharing options...
shercoben12 Posted July 8, 2014 Report Share Posted July 8, 2014 (edited) yeah tht year was a weak point, after that they have made it abit stornger but it still does occur much to our annoyance !!! sometimes when the idler gets chipped if it engages to the clutch basket at a chip or at a bad angle the clutch case will flex and crack or break. this happened on our old 2011 300. ££££ Edited July 8, 2014 by shercoben12 Quote Link to comment Share on other sites More sharing options...
smalley250 Posted July 9, 2014 Report Share Posted July 9, 2014 Me too on 300 07. Mega bucks to buy casing and idle gear, thats how they stay in business. Quote Link to comment Share on other sites More sharing options...
andyc607 Posted July 14, 2014 Author Report Share Posted July 14, 2014 Thanks for your replies.. when i get a minute to spend some more time on it I will post a pic of the kick shaft and pawl gear. I realise that £££'s will have to be spent, hoping its jst the casing, and idle gear. I really don't want it to happen again once i get it back together. Lineaway: what should i be looking for on the shaft and pawl gear, just any signs of damage? Much appreciated advice. Thanks Quote Link to comment Share on other sites More sharing options...
lineaway Posted July 14, 2014 Report Share Posted July 14, 2014 The pawl on the kick start shaft will be damaged. You have to buy the new shaft with matching pawl. The new updated pawl will not fit the old shaft. Quote Link to comment Share on other sites More sharing options...
lineaway Posted July 14, 2014 Report Share Posted July 14, 2014 This is an example. The picture on the left is a good `03 shaft. The broken one in the middle and the one on the right are not compatible as the pawl will not interchange. All three are different. Quote Link to comment Share on other sites More sharing options...
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