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2005 trx 450r kick starter jamming up..
This kick starter was jammed up. Meaning that I would push it forward and it would stop. Wouldn't go any further. I took the spark plug out and put it in gear and rolled it and the engine turns over fine. I pulled the side case and the first thing I found was that someone had screwed with this thing and the ratchet spring, #5 was in between the gear, #2 and the ratchet, #4. So, I thought that was the problem but no it's not. I removed the clutch/basket to check the idler gear, #6 and it checks out. I measured the i.d and according the manual it's within service limit. I then checked the spindle,#10 and pinion gear,#2 and they are in spec, although, barely. If I turn the primary gear with a socket while pushing the kicker it will cycle thru. If I remove the clutch basket and cycle the kicker it works perfectly. But, when I put the basket back on and it puts a load on the gears then it jams up. I thought that maybe that the first idler gear assembly was wobbling bit and causing a bind, so I put the side case on with a few screws and it does the same. If I turn the crank with and allen wrench thru the hole in the side case, then it will cycle thru. All of the bearings that are involved in the whole assemble are all good. Nice and smooth.
Last edited by hondanutz; 12-07-2019 at 11:25 PM.