Hi I got a 05 pro 280 recently, LOVE IT. just geting back in to trials after a few years at 45.My questions are, bike dosen't have a kill swich what wires do you use on that and bike has a rattle at idle souds like a loose timing chane on a four stroke, checked all bolts noise goes away under a lode.Makes this noise in gear in neutrule, clutch in clutch out.

This forum is great

Thanks in advance

Patrick

Hi I got a 05 pro 280 recently, LOVE IT. just geting back in to trials after a few years at 45.My questions are, bike dosen't have a kill swich what wires do you use on that and bike has a rattle at idle souds like a loose timing chane on a four stroke, checked all bolts noise goes away under a lode.Makes this noise in gear in neutrule, clutch in clutch out.

This forum is great

Thanks in advance

Patrick

Patrick,

Go to this site: http://www.trialspartsusa.com/tech.html and you'll find a bunch of stuff that will help you, including the wiring diagram to hook up the kill switch. Use a two-wire grounding switch like a YZ250 type and the KX250 switch also works well, I've never had a problem with those switches, rain or shine.

I'd pull the clutch sidecover and check the kickstart idler gear to start. The clutch will usually be a little rattley but the noise will go away when the clutch lever is pulled in.

Jon

John ,

Hello I pulled off the side cover what should I look for. Andthe kick starter shaft came partialy out and sounded like a spring unwound? Is there somthing to wind back up?

Thanks Patrick,

John ,

Hello I pulled off the side cover what should I look for. Andthe kick starter shaft came partialy out and sounded like a spring unwound? Is there somthing to wind back up?

Thanks Patrick,

I think so. Look on the same website for the GasGas engine update for Feb 2008 and you'll find info on how to set the kickstart mechanism. When taking the sidecover off, it's a good idea to lightly tap on the kickstart shaft to keep it in place as the cover is pulled back.

Did you ever get that water pump fixed?

Jon

Jon,I instaled the water pump kit you got me and it fixed my coolant leak. I watched the video on tacking off the clutch basket so I can inspect kickstart idelergear .In the video he pulls the clutch out by hand and says no tools required. mine want budge,my bike is 2005 280 pro should it be the same as the bike on the video or do I need to loosing something?

many thanks Patrick

Jon,I instaled the water pump kit you got me and it fixed my coolant leak. I watched the video on tacking off the clutch basket so I can inspect kickstart idelergear .In the video he pulls the clutch out by hand and says no tools required. mine want budge,my bike is 2005 280 pro should it be the same as the bike on the video or do I need to loosing something?

many thanks Patrick

Patrick,

Down inside the center of the hub (you may need a flashlight) is a special stepped washer held in by a special 4mm Allen capscrew (it has a hole drilled down the center). The head of the capscrew is shaved down to give a little more clearance for the clutch servo cylinder to drop down into the hub. It is VERY IMPORTANT to use a new Allen wrench or an old one that has about 5mm cut off the end so that the flutes are sharp and will grip the center of the capscrew, otherwise you will strip out the capscrew and it's a bear to get at to back it out. Use a small hammer to rap the top of the Allen wrench (use a T-handle) to shock it loose and it should come out fairly easily (keep pressure on the Allen wrench while turning it). The capscrew shaved head is about half as deep as a regular one and really easy to strip out. Some riders leave the washer and capscrew out, relying on the pressure exerted by the servo cylinder to keep the basket pressed down as it makes it easy to get at the shift shaft centering mechanism in the field but I like to keep them in.

If the hub still sticks you can carefully use a couple of slotted screwdrivers on each side of the hub to lever it out slowly and be careful not to damage any parts or sealing surfaces.

Jon

Edited January 29, 200917 yr by JSE

Jon,

got the clutch off,idler gear shot!!! over half the teeth badly chiped four are over half gone and next to each other. funny thing is cant find any bits in the cover.Could the bad teeth couse a fairly loud ratle? Whats a new one cost?

Patrick,

Jon,

got the clutch off,idler gear shot!!! over half the teeth badly chiped four are over half gone and next to each other. funny thing is cant find any bits in the cover.Could the bad teeth couse a fairly loud ratle? Whats a new one cost?

Patrick,

Patrick,

You'll need to find all the little pieces or, most assuredly, they will find the little spaces in between your gears. Yes, the idler gear with missing teeth can make that nasty sound.....

Jon