crombie Posted January 6, 2015 Report Share Posted January 6, 2015 I bought a 2009 sherco 290 with a engine knock. I was told it needed a full rebuild. I took of the clutch cover as I could feel the gear lever spring had snapped. I found the snapped piece had gone between the clutch basket gear and the small gear that drives it and chewed up a tooth so every rotation it would knock. I managed to file it down a bit but to get it running smooth I had to file a bit much and now there is a bit of slack between both cogs and now I have a new knock. If it possible to put some weld on the tooth then file it down until it's smooth and knock free or do I have to spend £260 on a new one ?? Quote Link to comment Share on other sites More sharing options...
suzuki250 Posted January 6, 2015 Report Share Posted January 6, 2015 A replacement from a breakers is your best bet Quote Link to comment Share on other sites More sharing options...
tony27 Posted January 6, 2015 Report Share Posted January 6, 2015 Sorry to say it but unless you can put up with the noise you'll need to replace the gear, it shouldn't be welded as the gears are case hardened & you'll just end up with teeth that could snap off causing a lot more damage It could be worth looking on ebay for a clutch basket from a breaker, part number for the gear is the same from 99-2010 1 Quote Link to comment Share on other sites More sharing options...
crombie Posted January 6, 2015 Author Report Share Posted January 6, 2015 I thought as much. Iv not actually had it running since I filled it down but I might try it tomorrow Quote Link to comment Share on other sites More sharing options...
wakka Posted January 6, 2015 Report Share Posted January 6, 2015 Quote Link to comment Share on other sites More sharing options...
toetoe Posted January 7, 2015 Report Share Posted January 7, 2015 try this guy, ebay item number 301444547591 he had a sherco he was breaking, i wanted a water hose, he wasn't advertising it but i emailed him and he had got the exact part with the sensor, it went strait on, if he has got what you want he will probably ask you to say a price so start off low. Quote Link to comment Share on other sites More sharing options...
copemech Posted January 7, 2015 Report Share Posted January 7, 2015 The small gear is inexpensive. Quote Link to comment Share on other sites More sharing options...
crombie Posted January 7, 2015 Author Report Share Posted January 7, 2015 Yes the small gear is only £45. But the large gear is £220 or £260 with basket Quote Link to comment Share on other sites More sharing options...
copemech Posted January 7, 2015 Report Share Posted January 7, 2015 Yes the small gear is only £45. But the large gear is £220 or £260 with basket I presume you paid accordingly when you bought the bike? Nothing lost then, fix it correctly, and throw in some Viton crank seals from splatshop while you are there! Still cheaper than a complete teardown and rebuild with bearings and rod kit! Quote Link to comment Share on other sites More sharing options...
shercoben12 Posted January 7, 2015 Report Share Posted January 7, 2015 call this guy, he will definitely have one in stock . http://www.allensusedtrialsspares.co.uk/ Quote Link to comment Share on other sites More sharing options...
crombie Posted January 7, 2015 Author Report Share Posted January 7, 2015 I think I got it very cheap for a 2009 290. It's not without issues tho. It needs the rear shock rebuilt. New rear mudgaurd. Linkage bearings and this engine problem. Does the engine not need split to do crank seals ? Quote Link to comment Share on other sites More sharing options...
tony27 Posted January 7, 2015 Report Share Posted January 7, 2015 To do seals the cases don't need to be split, I've never replaced just the seals because I've always been doing main bearings at the time but they do fit from the opposite side of the cases from the bearings Normal way to remove them with the motor assembled is to carefully wind a self tapping screw into the seal & use vice grips or similar to pull on the screw to remove it Quote Link to comment Share on other sites More sharing options...
crombie Posted January 7, 2015 Author Report Share Posted January 7, 2015 Ah rite I always assumed it needed split. I'm going to try running it the way it is with the filled down tooth to see what it's like. Hopefully my order from splatshop will be here tomorro Quote Link to comment Share on other sites More sharing options...
copemech Posted January 8, 2015 Report Share Posted January 8, 2015 Had one the same and tried fileing down the gear and using a new small gear, it still knocked, apparently distorted the tooth enough to do so, although could not really see it. If you pop the small gear off, the seal pops out easy with a little lever, I use a small dent popping slide tool to break the gear loose off the shaft, don't take much, but often more than prying against the case will get you, as you will damage case. Let us know how you get on. Quote Link to comment Share on other sites More sharing options...
crombie Posted January 8, 2015 Author Report Share Posted January 8, 2015 All my gaskets and seals came today so I got the engine built back up. You can slightly hear the worn tooth on idle but on throttle it's completely gone. I think the clutch may be slipping but Iv still to test it. I also need to replace the small end bearing but so far so good on my £180 bike . Iv got a video of before and after if anyone is interested. It's YouTube links http://youtu.be/nivHDCwonQ0 (before) http://youtu.be/p2rWbHlHeUk (after) Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.