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Johnst300

2010 gasgas 300 kick start problem?

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Hi there, my friends got a 300 gasgas and through stupidity and frustration he has kicked the kickstart over repeatedly and very hard and it no longer feels to engage. You can push it down with your fingers but it does spring back to the top. Any ideas on what part he’s broke and how big of a job it is to fix?

cheers

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Your mate has passed the rite of passage and can now call himself a real GasGas owner.

First commandment of GasGas ownership is that:
Thou shall not kick full blooded until gear has meshed

99% likely he has broken the kickstart gear, so should be an easy fix as long as he hasn't taken anything with it.

 

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At minimum he broke the Bart gear. Maybe need the idler gear and spring too. Just have take it apart.

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Clutch cover off and that’s what I found, piece of cog was down near the shaft any ideas on what’s next?

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Get a 7mm 12 point socket to take apart the clutch. You will have lots of debris to clean out 

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The whole clutch basket needs to come off. It is the single bolt in the center. That is the idler gear that is broke.

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with the idler gear broken, be sure to check over the "Bart" gear on the kickstart shaft for damage as well.

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The idle gear is actually fine the piece you see broken here is the bart gear 

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45 minutes ago, Johnst300 said:

The idle gear is actually fine the piece you see broken here is the bart gear 

Originally i thought it looked like the bart gear. As for the idler, you won't know until you rebuild it. A slightly damaged tooth on the idler gear can create a very annoying rumble/ticking when the bikes running and turns against the clutch basket.

Edited by faussy

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Check the replacement Bart gear very carefully, no tiny indentations, scratches or burrs on the teeth...all can lead to hairline cracks developing eventually ending up as you found. I think the recess machined into the gear body is the problem, it may be there to allow clearance for some other mechanism but its made the gear very thin in my opinion...no pun intended🙂

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