Kick starter seized help?

is the key in place for the counterweight? Could it have sheared? Shaft broken? If the counterweight wasn't properly installed, and/or the key had a defect, it could have let go. I recently had a yamaha generator have a improperly installed rotor, and it spun when the key failed.

Hard to tell from a single picture.

Also seems weird to have this fail and onegreyghost's clutch screws back out. QC problem at the factory? it's hard to say w/o knowing frequency and raw numbers of failures.
 
Yes the end of the shaft that goes into the impeller is sheared off on the face were the key couples to the impeller bearing. If the shaft sheared though don't you think the key would fall and the shaft would just spin without turning the impeller? The shaft is obviously sheared but I don't know how the pressed bearing then ground down the case and finally let go? I have more pics of the parts I'll post later today
 
I don't see how the counterweight could be the source of the problem. Even if the key sheared, it is a close fit on the crank and captured between the collar and the primary pinion, which is obviously secure. For the weight to move into the case and chew it up would mean the entire crank would have to move. There is a circlip on the back side of the plastic gear retaining it engaged against the drive pin on the shaft. Have you found this? Perhaps this failed or was missing, allowing the plastic gear to "walk" back into the weight, catching the edge of the eccentric. There would be a tremendous amount of side load force working on that shaft at that point, as is obvious in the totally shattered bearing, snapped shaft and damaged case.

Look for that circlip, or the part of the shaft without it.
 
OK, my $$ is on the shaft simple failing where the pin is pressed in, wobbling, and getting caught by the weight. Like I said this has happened once before, but it was awhile ago and my not be available.
 
ok so i dropped the bike off at my dealer and there taking care of it, i figured they would there all great guys and they said dave at gasgas pacific said there going to get everything fixed up asap so a big thanks to both my dealer(seitzco motorsports in okotoks!) and dave at pacific. finally a company that stands behind there bikes!!!!
 
nambo-trev said:
ok so i dropped the bike off at my dealer and there taking care of it, i figured they would there all great guys and they said dave at gasgas pacific said there going to get everything fixed up asap so a big thanks to both my dealer(seitzco motorsports in okotoks!) and dave at pacific. finally a company that stands behind there bikes!!!!
Click to expand...

Good for them, great to see someone doing what is right instead of trying to send the blame back to you. Just one more thing to love about GG! BMW and Suzuki should take notice (from what I hear).
 
I just thought I'd also mention that seitzco( my dealer) offered me a 2010 ec300 demo to use while my nambo was out of commission, now that's good service, thanks again guys!!!!
 
alright everyone so heres whats going on, my dealer has taken the engine apart because one of the ball bearings was missing. so after tearing it down they needed to replace water pump and get a new set of cases. ive been waiting for a week to see how long parts are going to take to get so i called today to ask whats going on and how long my bike is going to be down for. they talked to dave fair today and told me that a new motor is currently being shipped from spain for me! now i was really impressed with how gasgas stepped up in fixing my bike but this is just great service in my opinion, no messing around with new cases just a brand spankin new motor. thanks dave!
 
Dave IS the man , Nobody takes care of his customers better than Dave , but I'm biased , as he's my friend and dealer. I was at his shop today and he told me about the new motor coming to you , i wasn't surprised at all. He stepped up and took care of things , unfortunately it does take a few days to get things out of Spain , but you will be Rockin the Nambo again soon !!
 
Just another fine reason why I love this brand. There is nothing more comforting than having a company that stands behind their product like that. Great dealer, great distributor, and great OEM. Oh yeah......and a great bike. What more can one ask for?

One of the many reasons I choose not to ride a pumpkin anymore!
 
yup, dave is the man for sure, ive never had a dealer/distributor ever go out of there way for anything(and ive bought alot of bikes!). once a dealership has your money they dont want anything to do with you let along follow you threw the process of a repair. it really is nice to know that there is a distributor/dealer/brand that really takes care of there customers. it will all come back around to, as there are many people that ride with me looking at a gasser instead of there long time KTM because of such service!
 
Maybe Dave can get me a new motor for my 06. the same exact thing happened to me the impeller shaft sheared off at the pin and blew a hole into the bottom of the inner clutch cover.
 
nambo-trev said:
you nailed it aflica, i took the cover off today and the water pump had completely exploded sending chards of metal throughout the case as well as plastic from the gear(thats tore in 2). the insert were the shaft goes is severely scored and bearings are everywhere, heres some pics
Click to expand...

This scares me a bit as I have on my mind,for some time now, to buy a GasGas. Nambo-trev, what guaranties do you have this won't happen again in the future ? Is there anything we could do to prevent this ?
I know of a similar case here in Portugal but it happened to a 2010 Sixdays 250.
 
Nambo- I did get some markings on the case but I think it can be salvaged. Luckily it blew a hole in the inner clutch cover which let almost all the parts out of the motor.


I'm not sure of this but for a while I had been able to smell anti-freeze. I kept checking the level and it was fine but could still smell it and even other people I was riding with commented. I don't know if it's an indicator of the problem but thought I would throw it out there.
 
Looking at this logically it could be from one of three things:

1)The shaft could be faulty (brittle/weak) in the thin area of the pin where its pressed in

2)A bearing could have failed causing excess load on the shaft across the pin as its driven by the gear through this point. Then its a pissing contest between the plastic gear teeth and the shaft.

3)Debri in the trans/primary lodged between the primary pinion and the waterpump gear, placing a tremendous side load on the weakest part of the shaft.

Tough to analyze once it all goes to hell with a case full of fragments. Did you have any coolant in the oil when you smelled it? Maybe pump seal, bearing, shaft failure mode. Just a thought.
 
Nope, no mixing of the oil and water.

I would say the bearing in the crank case failed at the end of the shaft or the shaft snapped and wrecked the bearing
 
sounds identical to what happened to me. did the bike take a slight lay down on the right side before all this happened or did it just let go?
 
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