Kickstarter gear repair

[3hunerd]

Hey all,

I was thinking of tackling this on my 05 250EC, and I was curious if you needed to remove the clutch basket to do so. My dealer was walking me through this, and he was not quite sure if you needed to remove the clutch basket. Anyone know for sure?

Thanks!

[JoshP]

You will need to remove the clutch basket to do this job.
It's pretty easy but be prepared to replace the kicker and ratchet gears which you can take a look at using the parts fische on GoFasters.com http://www.gofasters.com/index.php?m...x&cPath=65_134
I just did this and replaced the following parts in the process.
RATCHET PINION SPRING $8 (Part#1)
KICKSTART RATCHET PINION $26 (Part#2)
STARTING PINION $70 (Part#6)
KICKSTART SPRING $11 (Part#11)

It was pretty quick to do the job but a pain to line all back in the cover without pinching it so once the bolts are in the engine cover check the kick functionality prior putting oil back in. Good Luck

[3hunerd]

Thanks for the info Josh. I just wished I had done this a month ago!

[LAWMAN]

mine ('07 300) needed this too, but I had the dealer do it. must be a weak spot in the design.

[steve]

Make sure the nub on the ratchet goes under the catch!There is a plastic collar with a groove in it,that groove goes over the spring end on the shaft.Spring should have tension on it when assembled.Do your test runs without gasket so not to ruin it.You might have to tap the case cover and use some wooden shims to get it of so not to gouge gasket surface.Good Luck!

[gasser]

The problem on the 07s was a weak RATCHET PINION SPRING. If you have a newer gasser that the starter gears sometimes skip and don't engage - change the spring before the gears are damaged. The problem won't go away it will just get worse if you don't change the spring. You might be able to stretch the spring to increase it's tension as a temporary measure while you order the new spring. Hopefully Gas Gas is taking steps to make sure the new springs are stiff enough. - Ken