nip3pin Posted January 9, 2011 Report Share Posted January 9, 2011 Hello guys, I am new to this site but not new to trials, I have owned bikes since I was 6 years old, I am now 40 going on 41 this March. Altough I have been out of trials for a few years due to road racing I have recently bought a 2003 Sherco 2.9. I believe I paid a good low price for it as it had a few rattles especially from the top end. On getting it home I instantly had it in bits. New piston, rings, little end bearing, water pump bearings and all the seals later and it's running sweet. The bike has been running brilliantly for 2 months or more now until today. Started up as normal on third kick, full choke no throttle. Had been riding the bike for 20 mins or so when I tried an ambitious hill climb. As I was breaking over the top I lost rear traction and bailed off to the right of the bike. The bike came over backwards. The wheels where up the hill and the tank down. Unfortunately the throttle stuck in the ground at approx 3/4 throttle. I clambered back up the hill to the bike to hit the kill switch, the bike did stop but I'm not so sure the kill switch was the cause or something else gave way first. The bike will not start now. I have a nice spark and fuel is flowing. When kicking it over I occassionally get a backfire with blue flames from the exhaust. Compression seems fine. I have a friends 2006 2.9 in my garage and there doesnt seem to be any difference in resistance when kicking over. I have no problems with stripping the thing down, however it may be that one of you fine gentlemen may know an easier solution. Timing or drift key etc. I would be very grateful of any input. Kind Regards Jason Quote Link to comment Share on other sites More sharing options...
ormplus Posted January 9, 2011 Report Share Posted January 9, 2011 check the woodruf key in the flywheel,its probably sheered.if the engine was reving that much the kill switch wouldnt stop the engine. cheers willie. Quote Link to comment Share on other sites More sharing options...
02-apr Posted January 9, 2011 Report Share Posted January 9, 2011 Most likely the Woodruff key positioning the flywheel on the ignition side has sheared resulting in the timing having slipped. With your racing experience I won't insult you by explaining further as you'll be easily able to cope with such a repair. Quote Link to comment Share on other sites More sharing options...
nip3pin Posted January 9, 2011 Author Report Share Posted January 9, 2011 Thankyou ormplus and 2/4 for your prompt replies. I have ordered a flywheel puller and woodruff key from ebay. As soon as they arrive I will keep you posted on my progress. Thanks again Jason Quote Link to comment Share on other sites More sharing options...
copemech Posted January 10, 2011 Report Share Posted January 10, 2011 Probably on track here. Only other thing I might suggest is while you are waiting, you might nip up some type flywheel holder or strap wrench so that you can properly torque up the flywheel nut after repair. These things are supposed to go up to 73 lb/ft or 100 nm as I recall, and you don't want them too loose, or risk damaging the crank by over tightening. Once pproperly set, I scribe index marks on the shaft and nut using tha small dremel disc, then once you have the ref marks, you can re-set things if need in the future, quickand easy using a rattlegun. Cheers, Quote Link to comment Share on other sites More sharing options...
nip3pin Posted January 15, 2011 Author Report Share Posted January 15, 2011 Hello Guys, Thanks for all your ideas and suggestions, you were all smack on. New woodruff key installed and tightened up as suggested. Bike has not run for over a week and started with the second kick, full choke no throttle, that's one kick better than ever, bike also seems to rev and pull a little better although I did thoroughly clean everything then advance the ignition slightly. Once again thankyou to all..... Regards Jason Quote Link to comment Share on other sites More sharing options...
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