Hey, I took off my clutch to put a circlip and washer on the shaft the idler gear is on because it wasn't there to begin with. So I put everything back on and the kickstarter gear would grind when I kicked it down.Instead of meshing with the idler gear it would go past it. I checked everything and the springs were in the right places and the arm on the shaft rested against the case like it was supposed to. The gears are fine and nothing is bent or anything. I think the problem might be that the spacer isn't holding the gear back from coming out too far?? Also, when I put the clutch springs back in I tightened one of the bolts and it just stripped and popped out. How much should I tighten it?

 

i had the same problem with mine. somehow, my spacer slipped out and the gear would slip all the time. so i got a new spacer, circlip, and spring and it worked fine. you have to make sure the circlip is all the way in there because if not, it will mess up your whole motor. mine slipped off and some how the threads came undone and ruined my whole crankshaft, pistons, rods, and everything else. so i just took it to Super Bike Shop and they rebuilt the whole motor and now it runs like a beast! so before you ride, make sure everything is TIGHT and in place, you probably dont want to spend $2,800 on a re-build!!! -Jiz

 

You got the circlip for the idler gear right? Is there one on the kickstarter shaft?