Johnst300 Posted August 9, 2020 Report Share Posted August 9, 2020 Hi there, my friends got a 300 gasgas and through stupidity and frustration he has kicked the kickstart over repeatedly and very hard and it no longer feels to engage. You can push it down with your fingers but it does spring back to the top. Any ideas on what part he’s broke and how big of a job it is to fix? cheers Quote Link to comment Share on other sites More sharing options...
kurtas Posted August 9, 2020 Report Share Posted August 9, 2020 Your mate has passed the rite of passage and can now call himself a real GasGas owner. First commandment of GasGas ownership is that: Thou shall not kick full blooded until gear has meshed 99% likely he has broken the kickstart gear, so should be an easy fix as long as he hasn't taken anything with it. Quote Link to comment Share on other sites More sharing options...
lineaway Posted August 9, 2020 Report Share Posted August 9, 2020 At minimum he broke the Bart gear. Maybe need the idler gear and spring too. Just have take it apart. Quote Link to comment Share on other sites More sharing options...
Johnst300 Posted August 10, 2020 Author Report Share Posted August 10, 2020 Clutch cover off and that’s what I found, piece of cog was down near the shaft any ideas on what’s next? Quote Link to comment Share on other sites More sharing options...
lineaway Posted August 10, 2020 Report Share Posted August 10, 2020 Get a 7mm 12 point socket to take apart the clutch. You will have lots of debris to clean out Quote Link to comment Share on other sites More sharing options...
lineaway Posted August 10, 2020 Report Share Posted August 10, 2020 The whole clutch basket needs to come off. It is the single bolt in the center. That is the idler gear that is broke. Quote Link to comment Share on other sites More sharing options...
zippy Posted August 11, 2020 Report Share Posted August 11, 2020 with the idler gear broken, be sure to check over the "Bart" gear on the kickstart shaft for damage as well. Quote Link to comment Share on other sites More sharing options...
Johnst300 Posted August 11, 2020 Author Report Share Posted August 11, 2020 The idle gear is actually fine the piece you see broken here is the bart gear Quote Link to comment Share on other sites More sharing options...
faussy Posted August 11, 2020 Report Share Posted August 11, 2020 (edited) 45 minutes ago, Johnst300 said: The idle gear is actually fine the piece you see broken here is the bart gear Originally i thought it looked like the bart gear. As for the idler, you won't know until you rebuild it. A slightly damaged tooth on the idler gear can create a very annoying rumble/ticking when the bikes running and turns against the clutch basket. Edited August 11, 2020 by faussy Quote Link to comment Share on other sites More sharing options...
section swept Posted August 11, 2020 Report Share Posted August 11, 2020 Check the replacement Bart gear very carefully, no tiny indentations, scratches or burrs on the teeth...all can lead to hairline cracks developing eventually ending up as you found. I think the recess machined into the gear body is the problem, it may be there to allow clearance for some other mechanism but its made the gear very thin in my opinion...no pun intended? Quote Link to comment Share on other sites More sharing options...
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