renegade master Posted November 17, 2013 Report Share Posted November 17, 2013 Hi guys, recently a buddy of mine took my gas gas 280 txt pro out for a warm up spin, when he came back the bike was stuck in second or frist gear ( i cant remember) and the gear peddle was at the 11 o clock position rather than the normal 9 o clock position, we couldnt change up nor down!, on inspection we removed the clutch cover and found a mangled up "shift shaft return spring" and a bit of metal filings as well, also the inside of the clutch cover was damaged where the clutch release arm was rubbing up against it, I think that bit was due to not having the clutch hub bolt in it! anyway I though this would be an eazy fix! but the other day I was practicing balance on an other bike in the shed when I knocked over the gas gas and it slid down on it side with no damage to it! but when I picked it up and put it back on its side I seen some bearing needles laying on the casing below where the clutch fits..... and not just that but to make things even worse theres two different sizes of needdles in it! I am thinking that when the bike was on its side these needles rollers fell out from the crank case? ....... I am wondering should I say "can anyone help" or is this just a aother gas gas horror story!.... anyway I am thinking it could be some bearing off the gear set? it might also be the crank shaft bearing or the kick shaft bearing as well? But it is not the clutch end plate bearing..... I think I need to strip the lot down to see! grrrrr I would say thats a pain in the rear! Any opinions? Any advice? Any scrap dealers? lol ps I have attached some pics of it Quote Link to comment Share on other sites More sharing options...
lineaway Posted November 17, 2013 Report Share Posted November 17, 2013 So the real story. Did you knock the kick start shaft out and shove it back in for the picture? Quote Link to comment Share on other sites More sharing options...
lee99780 Posted November 17, 2013 Report Share Posted November 17, 2013 There's 2 bearings that go on before the clutch goes on the shaft. Are they from there? Quote Link to comment Share on other sites More sharing options...
renegade master Posted November 17, 2013 Author Report Share Posted November 17, 2013 Lineaway, Does the kick start shaft look wrong? thats the way it always was..... it sways side to side..... is it ment to be straght? Lee99780, I hope your wrong about the other 2 bearings! I am pritty sure theres only 1 and its called the clutch end plate bearing Quote Link to comment Share on other sites More sharing options...
lineaway Posted November 18, 2013 Report Share Posted November 18, 2013 No, the small bearing looks like it could be from the blind bearing on the end of the kickstart shaft. You might post a picture of the other parts to see what`s missing. Quote Link to comment Share on other sites More sharing options...
lee99780 Posted November 18, 2013 Report Share Posted November 18, 2013 Im afraid theres definitely 2 needle roller bearings side by side that the clutch slides on over the crank. I remember it being a bit awkward to get tge clutch over both. Quote Link to comment Share on other sites More sharing options...
jse Posted November 18, 2013 Report Share Posted November 18, 2013 Im afraid theres definitely 2 needle roller bearings side by side that the clutch slides on over the crank. I remember it being a bit awkward to get tge clutch over both. Yes, there are two caged needle bearings with a thin wire circlip separating them. When the bearings are excessively worn, the rollers will fall out. Perhaps several became detached when the clutch hub was installed and as they would fall underneath the clutch assembly, they would not be noticed. Jon Quote Link to comment Share on other sites More sharing options...
biffsgasgas Posted November 18, 2013 Report Share Posted November 18, 2013 Jse is right. That's the bearing in the clutch basket that goes here. http://i211.photobucket.com/albums/bb71/biffsgasgas/058A4351-BD09-452B-B1CB-AAA1C32EB48D-8027-00000F49BDD94CE9_zpsa95b6325.jpg --biff Quote Link to comment Share on other sites More sharing options...
lineaway Posted November 18, 2013 Report Share Posted November 18, 2013 http://www.trialspar...iecepro2004.pdf The 2003 does not even show it in the manual. No wonder people do not think it is! Quote Link to comment Share on other sites More sharing options...
lineaway Posted November 18, 2013 Report Share Posted November 18, 2013 Sorry, page 60. My edit does not work. No wonder the cases appear damaged, clutch cover and center case. Quote Link to comment Share on other sites More sharing options...
jse Posted November 19, 2013 Report Share Posted November 19, 2013 Jse is right. That's the bearing in the clutch basket that goes here. http://i211.photobuc...zpsa95b6325.jpg --biff I would think that the damage to the two strengthing ribs above clutch shaft in the case may have been caused by the wobbling clutch basket (caused by the loss of needles in the hub bearings). Jon Quote Link to comment Share on other sites More sharing options...
renegade master Posted November 19, 2013 Author Report Share Posted November 19, 2013 Thanks guys for your help and input, its much appreciated, After reading your comments I would say your right about that hub bearing causing the damage, and the reason I didnt cop this was because I was looking at the manual that I had (same as Lineaway posted up page 60) This is a pitty as I have gone a little bit father with my inspection! wish I waited now! but maybe after something like that its better to inspect the lot and make sure the gear set is not damaged as well, I wonder why that bearning is not on the manual? does anyone know the part no.? Quote Link to comment Share on other sites More sharing options...
jse Posted November 19, 2013 Report Share Posted November 19, 2013 Thanks guys for your help and input, its much appreciated, After reading your comments I would say your right about that hub bearing causing the damage, and the reason I didnt cop this was because I was looking at the manual that I had (same as Lineaway posted up page 60) This is a pitty as I have gone a little bit father with my inspection! wish I waited now! but maybe after something like that its better to inspect the lot and make sure the gear set is not damaged as well, I wonder why that bearning is not on the manual? does anyone know the part no.? For the bearings (needs two)........MT280432039 Circlip spacer wire.........................MT280432139 Jon 1 Quote Link to comment Share on other sites More sharing options...
renegade master Posted November 19, 2013 Author Report Share Posted November 19, 2013 Thanks for that Jon. Quote Link to comment Share on other sites More sharing options...
biffsgasgas Posted November 21, 2013 Report Share Posted November 21, 2013 Again Jon, I agree spot on! clean it out and see what happens.' Renegade Master. Just make sure you get all of the slivers of metal out of there. Especially and I mean ESPECIALLY from inbetween the kick start 1/4 gear and the mating gear. The tollarances are so tight here that if you don't it will crack your outer clutch cover as the metal pushes the gears apart. --Biff I would think that the damage to the two strengthing ribs above clutch shaft in the case may have been caused by the wobbling clutch basket (caused by the loss of needles in the hub bearings). Jon Quote Link to comment Share on other sites More sharing options...
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