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xrstew

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About xrstew

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    TT Member

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    California
  1. Dave, thanks for the reply. The crank nut was indeed loose, and the key doesn't look that great. I will order a couple of replacements tomorrow. I have to replace the cover gasket anyway, it tore a bit when I took the cover off. Hopefully this will solve my problem. Late, J. Just took off the gear and lo and behold the key was completely sheared. Looks like it will be a fairly straight forward repair. I do wonder if this has anything to do with the fact that I have dual-sported this bike and I have ridden it on the pavement a bit. I seem to remember some issues with some of the pumpkins when it came to using them this way.
  2. Here's the problem, out on a ride, shut the 03 525exc down for a few minutes, then go to start it and the starter just spins and spins. Try to kickstart it and the same thing, it just spins like I have the decompression lever in. Finally resort to bump start and the bike starts right up but on the way back to the truck, the clutch starts to disengage like it is slipping or something. Right now I've got the clutch cover off and I can see no obvious defects or anything broken. Does anyone have any idea where to start? It seems to me it is probably something in the starter drivetrain? Any advice or help will be greatly appreciated. Long live thumpertalk!
  3. xrstew

    Clutch won't disengage.

    I think the stepped washer just got to the point where it was scored enough to create enough friction to stop everthing from turning. The wheel would turn, just had to really muscle it to get it to move. The friction plates were brand new, no wear at all. That's why I think the PO gave me such a good deal on the bike, He knew he messed up when he replaced the clutch, he just couldn't figure out what he did.
  4. xrstew

    Clutch won't disengage.

    Gotta love happy endings. Took the clutch freewheel off to look under the clutch basket hoping for something obvious. As soon as I took off the freewheel and the stepped washer and the two split washers, voila, everything started turning the way it was supposed to. Upon closer inspection, the stepped washer was put in upside down, so it was binding the whole thing up. Put everything back the way it was supposed to go and now the bike is just perfect the way it's supposed to be. I guess the PO must have done this when he replaced the clutch and couldn't figure out what he had done wrong. Thanks for all helpful suggestions, this is a great forum, and you can even have a free e-mail account to use it. I'm going riding tomorrow at Foresthill!!
  5. xrstew

    Clutch won't disengage.

    Wheel turns fine in neutral, I put it on the stand, started it in neutral, put it in gear and the back wheel takes off. If I am not mistaken, the back wheel should turn if the pressure plate is off because no matter what, there is no pressure to the plates causing the wheel to lock up. It shifts through all the gears if you don't stall it when you put it in gear from neutral on the ground. I guess I'll just have to keep taking it apart till I find something amiss. Thanks for the replies, should be able to report back something tomorrow.
  6. xrstew

    Clutch won't disengage.

    So I pulled off the slave, it looks normal. I put it back, I check the plates through the oil filler cap and they look like they are disengaging just fine. Pulled the clutch cover and removed the pressure plate, rear wheel still won't turn. ***? Shouldn't the the wheel turn at least some, there is no friction at all from the plates when the darn pressure plate is off. The clutch basket has zero grooves, could it be a bearing under the basket?
  7. I have an 03 450 EXC that I bought used a few weeks ago, right after I took it out for the first time the clutch started to make a huge squealing noise when I took off in first gear. Midway through my first ride the clutch stopped disengaging entirely. I had to get it rolling to put it in 1st and then I limped it to the truck. After reading several posts here and on ktmtalk I figured it was warped discs in the clutch pack. Pulled the clutch out, everything looked fine but since I had bought new clutch and springs I went ahead and replaced it. Bled the clutch through and through, fired it up and still no go, won't disengage. I plan on checking the slave housing, piston and o-ring. After that I guess it's a rebuild for the master cylinder. I just can't think of anything else it might be. The clutch appeared to moving back and forth just fine when I was pulling on the clutch lever with the clutch cover off. Sorry for the long winded post, if there is something else I should look at I would appreciate any suggestions.
  8. Went to the dealer today to buy a klx250s for the girlfriend and he told me its a 49 state bike!!! California sucks for sure. Can't plate anything, can't get a nice dual sport, AAAAARRRRGGGGHHHH!!
  9. xrstew

    3-1 at forest hill

    Hey Greg, we were parked at the threes, two couples and a buddy with his son. Our dog kept going over for some attention. We had a bunch of newbies and had a great ride. Did trail 2 after lunch and I was real proud of my sweetie for making it up the steep loose rocky hill after crossing a creek. That is a great place to stage from when you have newer riders. I'll say hi next time for sure. Sounds like your afternoon was interesting, I would love to get over to 5 sometime. Have to leave the girl behind for that one though. Later, James.
  10. xrstew

    Countershaft End Play

    Glad to hear those replies, one of the guys on our DS ride has an 02 BRP and his had no play so I thought uh-oh. But if a new one has play it should be ok.
  11. xrstew

    Countershaft End Play

    My 01 BRP has about 1/8" of end play on the countershaft. It's not the countershaft sprocket or the retainer but the shaft itself that moves 1/8" in and out of the case. I discovered this the night before a 256 mi. dual sport ride and I didn't have any problems on the ride. Changed the oil today and had no metal in the used oil or filter whatsoever. Just wondering if anybody else has had this problem. I'm guessing that one of the bearings for the countershaft is going bad because if they were wearing into the case I should have found metal in the oil or filter. I would like to put off tearing the engine apart for a few more rides this summer, just don't want to cause catastrophic failure. Any advice or ideas would be appreciated, James
  12. xrstew

    Countershaft End Play

    My 01 BRP has about 1/8" of end play on the countershaft. It's not the countershaft sprocket or the retainer but the shaft itself that moves 1/8" in and out of the case. I discovered this the night before a 256 mi. dual sport ride and I didn't have any problems on the ride. Changed the oil today and had no metal in the used oil or filter whatsoever. Just wondering if anybody else has had this problem. I'm guessing that one of the bearings for the countershaft is going bad because if they were wearing into the case I should have found metal in the oil or filter. I would like to put off tearing the engine apart for a few more rides this summer, just don't want to cause catastrophic failure.
  13. xrstew

    countershaft sprocket play

    Don't mean to hijack this thread but I have a similar question. My 01 BRP has in/out play at the countershaft itself. The whole shaft moves in and out of the case about 1/8". I noticed this the night before I took it on a 250 mile dual sport ride. Fortunately I had no problems but I am wondering if this is something that might lead to catastrophic failure. No problems shifting whatsoever, might have been just a little clunkier than usual but really not too noticable unless you knew the bike. Any help from fellow owners greatly appreciated. James
  14. xrstew

    Foresthill or Georgetown?

    Ray, I think the weekend before father's day would be good for us. Sat or Sun. whichever works. We can finalize next week sometime, looking forward to it. James
  15. xrstew

    Foresthill or Georgetown?

    Congrats to you and your honey on the new bike Bob, I think that will be the perfect bike for her. If you are talking about father's day weekend I won't be able to make it, but either weekend before or after would be fine, James
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