postmanpat Posted December 14, 2008 Report Share Posted December 14, 2008 Help!!!!!!!!!!!!! I've a 250 Pro '04,out riding today and 1/2 way through 3rd lap the kick start stopped turning the motor over,the lever still has return spring tension,but just spins the shaft Quote Link to comment Share on other sites More sharing options...
vgstef Posted December 14, 2008 Report Share Posted December 14, 2008 you probably broke the engagement gear . Quote Link to comment Share on other sites More sharing options...
vgstef Posted December 14, 2008 Report Share Posted December 14, 2008 picture of gear Quote Link to comment Share on other sites More sharing options...
nickj Posted December 14, 2008 Report Share Posted December 14, 2008 It could also just be the engagement gear has stuck on the spiral shaft. Mine did this a couple of years ago and simply cleaning it cured it and no further problems. N Quote Link to comment Share on other sites More sharing options...
manx2day Posted December 15, 2008 Report Share Posted December 15, 2008 My engagement gear broke last year. It was in perfect condition and it broke between the teeth and the hole where it goes on the shaft. Bit of a pain in the ass but lucky it didn't break all the teeth off and mess up the gear box. The spring tension was still there and it was spinning the shaft. Quote Link to comment Share on other sites More sharing options...
postmanpat Posted December 15, 2008 Author Report Share Posted December 15, 2008 Aye up lads,whipped the casing off this afternoon,the gear has sheared at the base,lucky me.....no other debris,just ordered the new bits plus a gasket,what coolant should i put back in? Quote Link to comment Share on other sites More sharing options...
jse Posted December 15, 2008 Report Share Posted December 15, 2008 Aye up lads,whipped the casing off this afternoon,the gear has sheared at the base,lucky me.....no other debris,just ordered the new bits plus a gasket,what coolant should i put back in? A 50/50 mix of automotive anti-freeze and distilled water seems to work well in most cases. Jon Quote Link to comment Share on other sites More sharing options...
manx2day Posted December 16, 2008 Report Share Posted December 16, 2008 (edited) I'm sure when you say coolant, you mean for the radiator? only asking as you have been working on the gear box, unless you emptied the radiator too!? What Jon says for the coolant mix. Edited December 16, 2008 by manx2day Quote Link to comment Share on other sites More sharing options...
jse Posted December 16, 2008 Report Share Posted December 16, 2008 I'm sure when you say coolant, you mean for the radiator? only asking as you have been working on the gear box, unless you emptied the radiator too!?What Jon says for the coolant mix. I thought the same thing too, but I checked just to make sure he mentioned "coolant". I think new owners may often not know that the water pump can just be pulled out and ziptyed to the exhaust pipe to keep it out of the way. Just be careful to "index" the pins on the W/P shaft to the slots on the crank primary gear when installing. There is a very thin o-ring that seals the W/P housing to the bore in the sidecover, so be sure to add a little grease to it and try to slide the pump housing in straight or the edge of the sidecase bore will catch the thin o-ring and damage it (the hoses exert a slight pull to the right, which will tend to cock it to the side if not forced in straight). Not a big thing, but you'll see trans fluid weeping around the W/P if the o-ring gets sliced. If it's trans fluid the question involved, Dexron ATF seems to work well in the 04's as it's a light viscosity and has good shear strength and anti-foaming properties (it's designed for a "wet clutch"/gear-tooth environment). It's inexpensive, so change it often as the Pro gearbox has a lot of extra things that the trans fluid lubes, like the crank main bearings and the internal roller in the main transmission shaft. There are several other trans fluids, like 5W/10W-30 auto oil and motorcycle trans fluids (I've tried Maxima "clutch saver" 75W with good results) that also work well and try to use a fairly light oil. I use GM AutoTrak transfer case fluid in my 02' Pro and really like it but I'm not sure how available it is to a lot of riders (o.k., I also like the pretty blue color too.....). Jon Quote Link to comment Share on other sites More sharing options...
postmanpat Posted December 16, 2008 Author Report Share Posted December 16, 2008 Cheers lads,i did mean water/antifreeze,i'm a bit fried at the mo,being a postie at xmas is fun!!!!!!!!!!!!!!,then my bike breaks.....just made my brain give up.I didn't know about the pump trick,so i dropped the antifreeze.....ah well.Bits coming thursday,i'll let you know how it goes. Quote Link to comment Share on other sites More sharing options...
postmanpat Posted December 18, 2008 Author Report Share Posted December 18, 2008 Hi,the bits have arrived,what a job to swap the gear over,any tricks on how to remove the spring? Quote Link to comment Share on other sites More sharing options...
postmanpat Posted December 18, 2008 Author Report Share Posted December 18, 2008 Got the gear swapped over,re-assembled,and re-installed in the motor,now the kickstart won't return,help........! Quote Link to comment Share on other sites More sharing options...
postmanpat Posted December 21, 2008 Author Report Share Posted December 21, 2008 Hi,getting p ssed off now,i think i've got the gear on wrong,can anyone tell me the correct position between spring and gear.spoke to gagas the other afternoon,but i must have misunderstood kev,got to get it done soon,i want to ride on 28th.Cheers Quote Link to comment Share on other sites More sharing options...
manx2day Posted December 22, 2008 Report Share Posted December 22, 2008 I know what you mean by that! I had similar trouble. You have to get the right tension on the spring by turning it. It was very difficult from what i remember and very annoying! I can't remember exactly how many turns etc but i'm sure someone will be able to help on that front. I had the gearbox back together about 5 times, each time realising that there wasn't any "spring" on the spring so had to dismantle and have another go! Took me a good few hours but got there. Good Luck!! Quote Link to comment Share on other sites More sharing options...
hrc1 Posted December 22, 2008 Report Share Posted December 22, 2008 Search for GasGasinfo on Youtube. Engine rebuild vids there.. Quote Link to comment Share on other sites More sharing options...
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