2019 EC300 Bendix cover removal?

B

BenS

New member
My 2019 EC300 starter has stopped working properly on only the second day of riding, so I'm going to do the "wet mod", but I want to pull the bendix out to make sure that nothing is binding.
The problem is that I can't get the Bendix cover off! Do I have to pull the circlip out(part 22 in pic) first, before disassembly, or should the cover come off easily?
p.jpeg

https://www.dropbox.com/s/jxfy6hx345qysd3/2019 Gas Gas EC300 Bendix.jpg?dl=0
 
Last edited:
BenS said:
My 2019 EC300 starter has stopped working properly on only the second day of riding, so I'm going to do the "wet mod", but I want to pull the bendix out to make sure that nothing is binding.
The problem is that I can't get the Bendix cover off! Do I have to pull the circlip out(part 22 in pic) first, before disassembly, or should the cover come off easily?
p.jpeg
Click to expand...

The cover just has three bolts and pops right off. It sits on there pretty tight so it takes a little effort. In the lower front corner there is a little tab you can use to lightly pry it. I usually just use the open end of a 10mm wrench
 
Thanks TGM. Yeah, I've tried prying the cover off, but it seems to be stuck to the bendix shaft. I'll spray some CRC in there to try to get it to loosen up.
The bendix gear isn't throwing out to the flywheel gear half of the time, so it usually takes two presses of the button to get it started. I've got a lifepo4 charger, so I'll charge the battery after each ride to make sure it spins fast enough.
 
BenS said:
Thanks TGM. Yeah, I've tried prying the cover off, but it seems to be stuck to the bendix shaft. I'll spray some CRC in there to try to get it to loosen up.
The bendix gear isn't throwing out to the flywheel gear half of the time, so it usually takes two presses of the button to get it started. I've got a lifepo4 charger, so I'll charge the battery after each ride to make sure it spins fast enough.
Click to expand...

I suspect your two problems are related. Sounds like the bendix is binding in the bendix cover which would cause the bendix to not turn fast enough to engage the flywheel. The bendix usually comes out with the cover though. I would try to get that off and clean it all up. If you have a dremel you can lightly polish the inside of the bendix cover and then lightly grease it all. I actually got an AS3 bendix cover and it seems to help it start smoother and easier.
 
Yeah, most likely related. It sounded like something was wrong from new, and I was actually expecting to find teeth broken off when I pulled it apart!
I wasn't expecting to have trouble with it, I thought the problems had been sorted from the 2018 model.
Yeah, I'll give it a polish in there. I've been reading up on the 2018 model threads regarding starter troubles. I'll definitely be doing the "wet mod", and I think they should come from the factory like that.
 
I've finally got the bendix cover off, it took a few taps with a hammer.
Even though the inside of the cover has been machined to make room for the bendix, it looks like it's been rubbing a bit. Parts 20 and 17 felt like they had small metal pieces interfering with their meshing, and they even locked up sometimes as I turned them by hand. I think I've managed to flush the pieces out, and I think the "wet mod" should help to flush any shavings out, as well as prevent shavings.
I'll probably drill and tap a hole in the bottom of the stator cover too, to put a little drain plug in, so that I can do oil changes easily.
 
You say the bendix isn't throwing out!
When you manually inspected it, does it feel like the bendix assembly doesn't work properly?
I've got a new EC300 Ranger 2019 and just had to sort my starter issue out.
My issue turned out to be the 2 right angle pinion cogs (items 20) not contacting properly due to the circlip (item 22)being dislodged at the bearing where the starter motor comes in.
According to the distributor it's a known issue.
 
Yeah, the bendix seems to be working properly, but I have seen a Youtube video in which the guy replaced the spring with a lighter one from a Honda bendix, which I wouldn't mind trying.
Yeah, the circlip is in place, and the gears are meshing ok, apart from having some debris in there.
 
Hi ben,

My starter was doing the same as yours, only working on the second tap of the button since new, almost a year without a starter and i decided to solved this no mather what.

Last night i took everything apart and inspected it very carefully, i discovered that the bendix cover, the hole where the shaft(part 16) that connects to the bendix, that hole is messed up, its not round as it's suposed to be, i also found that the bearing part 18 was also seized, i'm waiting on the parts from motocross center to test it, i'm very confident that this will solved the problem.

I will change the bendix cover and the 2 bearings. Inspect your bendix cover for any wear on both holes.
 
eralha said:
Hi ben,

My starter was doing the same as yours, only working on the second tap of the button since new, almost a year without a starter and i decided to solved this no mather what.

Last night i took everything apart and inspected it very carefully, i discovered that the bendix cover, the hole where the shaft(part 16) that connects to the bendix, that hole is messed up, its not round as it's suposed to be, i also found that the bearing part 18 was also seized, i'm waiting on the parts from motocross center to test it, i'm very confident that this will solved the problem.

I will change the bendix cover and the 2 bearings. Inspect your bendix cover for any wear on both holes.
Click to expand...

I replaced my bendix cover with the billet AS-3 bendix cover which is a much higher quality cover then stock and that seemed to make starting easier for my XC.
 
Hi eralha, Yeah, I'll inspect everything while I've got it apart, and use the dremel where I need to. I pulled the circlip out, and had a quick attempt at getting one of the bearings out, but it's in there pretty tight; I might have another go on the weekend.
Does that shaft(part 16) just pull out, or do I need to get the bearing(part 21) out first?
(I'm worried about breaking something if I apply too much force when I'm not s'posed to be, and would rather not have to order new parts!)
 
Last edited:
BenS said:
Hi eralha, Yeah, I'll inspect everything while I've got it apart, and use the dremel where I need to. I pulled the circlip out, and had a quick attempt at getting one of the bearings out, but it's in there pretty tight; I might have another go on the weekend.
Does that shaft(part 16) just pull out, or do I need to get the bearing(part 21) out first?
(I'm worried about breaking something if I apply too much force when I'm not s'posed to be, and would rather not have to order new parts!)
Click to expand...

Hi you need to take out the bearing(21) and then with the engine cover off the bike i put the tip of the shaft(16) on a vice, and with a rubber hammer i hit the engine cover so it could came out, do it gently to not damage the cover. the shaft(16) is screwed to bearing(18).

Inspect the cover(13) the hole where shaft(16) enter to see if there is any wear.
 
Just got this bike and I'm in exactly the same situation.

Any tips for removing bearing (21)? Did you use pullers with the gear still inside? Thanks
 
TerraMoto said:
Just got this bike and I'm in exactly the same situation.

Any tips for removing bearing (21)? Did you use pullers with the gear still inside? Thanks
Click to expand...

I took mine out this way:

Took out the starter and removed the lock nut on the bearing. Put the starter back again and hit the starter button just half a second, the force the starter does is enough to make it come loose. I know this isn't the best way but it worked for me.

Thanks
 
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