EC300 Kickstarter

[ECTim]

Hey guys, new GG owner here. Got an '06 EC300 today and it's clean with low hours. Any of you guys have issues with the kickstarter slipping? Previous owner said it did it since new but I'm not sure it should. It generally catches and will turn the motor and then goes straight down other times. He had replaced the shaft thinking that was it but it continued. I've read the springs are weak and won't push the cogs together and that fresh oil may help (which I plan to). If it's just a spring issue, I'm OK with it but if it's a gear issue, that's obviously more involved and an issue I don't want to have on the trail.

Thanks for any help!

 

[Jakobi]

It can originate from the spring being weak, but the weak spring and poor engagement on the gears can cause them to wear as well. Neither are hard to replace.

 

[ECTim]

Good to know, thanks!

 

[nokturnal]

I just went through this with my 06. It had been doing it for the past two years, getting progressively worse. I rode the bike to the point that it would only kick over 1 out of 10 tries (or more on the last day). Was hoping to get it to winter, but that didn't happen. I replaced the spring and gears with a known good bike and all is well. The gears that were removed showed CONSIDERABLE wear, though surely my procrastination did not help...

 

[fury1]

I have a spare set tim if you do decide you need them...take less than a half hour to swap them out...

 

[ECTim]

Thanks, Kev! I might be in touch but don't want to steal your spare set if I can get some. It does it like once every 2 or 3 kicks at the moment. Obviously I will need to order a gasket set too I'd imagine.

 

[Zman]

Check out the teeth on the ratchet pinion (item 4) and starting pinion (item 6). As they get older the teeth round off and do not engage well. If they look good you can probably stretch the spring to increase its preload a little or just replace it.

 

[Jakobi]

Thanks everyone for chipping in with the diamgrams and further info. I have a spare set siitting here from mine that I replaced. Mine would only do it every now and then. Like maybe once every ride or two. More spring related than teeth in my case, proven as I didn't change it and still get the occassional slip on new gears.

Try to avoid slap kicking the bike and take up the slack to TDC before giving it a smooth kick through and they'll last a lot longer too.

 

[KTMAndy]

Not sure if it's of any help. But my friends Gas Gas started having slopping problems after we had removed the clutch side engine cover. The water pump had been leaking.

After it was back together the kick start started to slip. We inspected the teeth and the spring. Checked that it had been wound in properly. Put it back together again.

This time the kickstart didn't return on the spring.

To cut a long story short after several more removals. It turned out that two engine bolts needed heli coiling the one to the left of the kick start and the base one under the clutch. It's worked fine since then.

 

[ECTim]

Thanks for the help folks! I'm going to pull the clutch cover and case to inspect it all.

 

[thebeav]

Kickstarter Slip

Me too! Just received a 2007 GG EC300 from a long distance buy with a slipping & clicking kickstarter. It will catch 1 out of 20 kicks. I read that this is a fairly common issue with Gassers that have sat for a period of time and, the blame is weak springs. I want to replace the springs but can't pull the kicker gears without first removing the Rekluse clutch basket. I can't get the flywheel nut off as I need a flywheel lock. Anyone have a solution besides an impact driver which I don't have?

 

[noobi]

Flywheel
1. I have in the past used a few ghetto methods, a nylon rope stuffed through the plug hole to lock up the crank. That should allow you to get the flywheel nut off, you will probably still need a puller though, same as Kawasaki 2 strokes iirc.

2. You can buy engine lock up 'plugs', which are like a spark plug body and thread but with a much longer and chunkier electrode end, which protrudes into the engine and stops the piston turning over TDC

If you're removing the clutch, you don't need to take the flywheel off, fyi.

Clutch
1. If you haven't got a clutch holder, you can make one out of a few old clutch plates bolted together with some sort of handle attached. This assumes you have old GG clutch plates around though.

2. Or, putting the bike in top gear and having someone stand on the rear brake as hard as they can, can work to lock up the gearbox and then the clutch hub nut can be removed with a power bar and socket.

 

[ECTim]

Time to get an impact gun, IMO....

 

[pscook]

Time to get an impact gun, IMO....

I'll be passing through Marysville on my way to Walker Valley Friday if you want to borrow my clutch holder tool. It works best with an impact, but I can loan you that, too.

PM me if you want to borrow my stuff.

 

[thebeav]

I'll be passing through Marysville on my way to Walker Valley Friday if you want to borrow my clutch holder tool. It works best with an impact, but I can loan you that, too.

PM me if you want to borrow my stuff.

Thanks Phil!!

I appreciate the offer. I took ECtims advice and bought an electric impact gun and the clutch basket is now off.

Found that 1/3 of the teeth of the ratchet gear (item 4 in the drawing below) were broken off. Will replace that and the spring and should be good to go.

I ordered a clutch retainer from Taskys and will need to reassemble so I can apply correct torque values.

The bright side about this is I got to buy new tools.

Thanks again tho!!

 

[Simmo737]

The bright side about this is I got to buy new tools.

Mmmmm tools, they're like donuts!

 

[ECTim]

The impact is nice to have. Bought one to do tire swaps at the house and I've used it on plenty of clutches and never had an issue. Just need to make sure you don't have it cranked up too high.

I'm working on a new spring setup and will inspect the gears while I've got it apart.

 

[thebeav]

Nice To Have!

Ya I can't say how many times over the years I wished I had an impact gun. Made all the difference.

Also look hard at the face of the gear that mates with the ratchet gear. I didn't see the wear but took it to the shop to order parts and they saw that I needed a new gear as well. After they pointed it out, I saw it clear as day. Always replace both as a pair I'm told. Always replace the spring too.