gasgasshetland Posted October 30, 2016 Report Share Posted October 30, 2016 Hi There, I have rebuilt my 2014 pro racing with new crank main bearings. All sounded good when rotating prior to putting in he clutch assembly. Whilst doing the rebuild I changed the kickstart half gear and the idler gear it contacts with as they were both damaged. Am now thinking that the clutch basket gear and the main gear on the crank will need to be changed having read that even hairline scratches can cause them to be noisy. I have inspected them and they look ok ,but can't think of anything else to try. It seems that the clutch basket and main gear are a matched pair at around £200. Has anyone any experience of the clutch basket causing a lot of noise. It doesn't go away with pulling in the clutch. Quote Link to comment Share on other sites More sharing options...
lineaway Posted October 30, 2016 Report Share Posted October 30, 2016 Did you get the KS timed correctly? Quote Link to comment Share on other sites More sharing options...
gasgasshetland Posted October 30, 2016 Author Report Share Posted October 30, 2016 Yes. I watched a video and saw pic of the correct position for the spring in relation to the gear. 1 Quote Link to comment Share on other sites More sharing options...
spenser Posted November 1, 2016 Report Share Posted November 1, 2016 I have found that if there is damage to either of those gears, it can often be removed with a die grinder or Dremel tool as you just need to remove a high spot that is causing the knocking sound. I have found damage on all four of the gears that you mentioned, but have always managed to salvage the clutch basket gear with a bit of dressing. The primary drive and the idler are easy to replace, and can be a bit of a bear to repair if the damage is too great. Spencer Quote Link to comment Share on other sites More sharing options...
sectionone Posted November 2, 2016 Report Share Posted November 2, 2016 Did you get the KS timed correctly? ^^this alignment is different than what is recommended here: https://youtu.be/h7disOibvEU?t=6m56s Quote Link to comment Share on other sites More sharing options...
lineaway Posted November 3, 2016 Report Share Posted November 3, 2016 HMMn, Pretty sure I got that picture off a Gas Gas update from Trialspartsusa years ago and it`s never failed me. Quote Link to comment Share on other sites More sharing options...
michael_t Posted November 3, 2016 Report Share Posted November 3, 2016 too bad Jim has been banned, it would be helpful if he could weigh in on his video... Quote Link to comment Share on other sites More sharing options...
gasgasshetland Posted November 10, 2016 Author Report Share Posted November 10, 2016 Got to the bottom of my issue. Turns out the new main bearings I installed are to wide. Correct size 22.95mm wide on the centre race. The one I took out thinking I done something wrong turned out to be 23.03 mm so no wonder it wasn't right. I had sent a video to factory Kev at GasGas uk and he told me of the issue of the Xiu bearings coming from the factory incorrectly machined. Now have managed to get a correct sized set so going to get them installed and hopefully that will it all be sorted. To say am p****d off with it is an understatement. 1 Quote Link to comment Share on other sites More sharing options...
worldtrialchamp Posted November 13, 2016 Report Share Posted November 13, 2016 Why was Jim banned? sounds extreme Quote Link to comment Share on other sites More sharing options...
fastbelly Posted November 13, 2016 Report Share Posted November 13, 2016 What a bloody ball ache. Quote Link to comment Share on other sites More sharing options...
aussiechris Posted November 16, 2016 Report Share Posted November 16, 2016 Yeah, anyone know why Jim is banned? He has done more to help Gas Gas owners than everyone else put together and as far as I know has never asked for anything in return or tried to promote his or any other business. Very disappointing news. Quote Link to comment Share on other sites More sharing options...
sectionone Posted November 17, 2016 Report Share Posted November 17, 2016 He explains it here: http://advrider.com/index.php?threads/the-other-trials-forum.1178143/ 1 Quote Link to comment Share on other sites More sharing options...
Andy Posted November 17, 2016 Report Share Posted November 17, 2016 Only just noticed this but Jim was not banned. He was warned repeatedly about promoting his business ventures yet carried on doing so. He was warned yet again and after a bit of toy throwing from pram he asked for his account to be removed. There is considerable cost, time and effort involved in providing this site and these forums. They do not exist for people to get free advertising. It is the only rule that is enforced and it is not an unreasonable rule. 3 Quote Link to comment Share on other sites More sharing options...
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