First of all hello, New member here. Bought a 06 sportsman 90 for kids for christmas. Couple of issues. Starter grinds? when engaged sounds terrible, will eventually start though. kick start will start the bike but usually takes 10 or 15 kicks, and doesnt like to come up on its own. I am assuming this is just a worn spring? My question is do I need to rebuild the starter or is a weak battery causing the binding noise? How hard is it to replace the spring in the kickstart? Also should it be so hard to start with the kick start? It is usually only when cold. when it is warmed up it starts on the first kick. Thanks in advance.

 

Welcome to the forums.

Is the starter bolted up completely?

 

I assume so. I haven't actually inspected it. I guess they can come loose?

 

Welcome to the forum! Starter grinding could be that the idle gear assembly behind the clutch cover that the starter engages has a few chipped teeth! I've found this a few times! Teeth are very soft!As far as kick starter sticking,this is another common problem,usually just need to pull the clutch cover(leave the kick starter on the cover!) blow out the belt dust and lightly lube the internal kick starter ratchet gear and pinion and lube the shaft.Another tip on starting when cold or if its been setting up awhile is to block off air tube with your thumb while starting,allows fuel to draw in cylinder quicker for easier starts! OPT

 

Yeah, that's what I meant to say OPT.

As always, great advice.

Spurdie, anytime you see a reply by OPT, the advice your getting is as good as gold.

 

Ok, thanks guys. I will check these things when I get home. I appreciate your swift responses.

 

So the kick start doesnt engage this same idle gear? Will I be abloe to tell if it is missing teeth when I pull off cover to lube?

 

Ok so I took the clutch cover off. Got the kickshaft working great. I think its the starter wheel thats causing the noise, all teeth are there, they just look worn a bit. starter turns fine as does the gear. However when i got everything back together it starts and idles fine but has no power, wont even move. will rev fine in neutral, but nothing in drive. What did I do? It ran fine before just starter problems. It also runs fine in reverse now, just not forward.

 

Ok, it looks like the front clutch is stuck in high gear for some reason, it won't let belt down. I fiddled with it for an hour without actually removing clutch and got nowhere. Any ideas? Will I have to remove it? The next question would ne how without an air wrench.

 

The front clutch sheath has to fit on the splines and held there with the belt on when you tighten the nut! If it slips, the clutch will not work properly! This is where an impact driver helps(as you hold the sheath and belt in place,just impact the nut on!) OR if you have a friend that will tighten the nut while you hold the assembly together! OPT