I bought a used 05 DS650 with very low hours by all appearances, Paint still good by footpegs and generally good appearance. I know the quad had been wrecked because the bars had been replaced and the bracket for the gauges was bent. The PO was upfront about the quad being rolled and the damage and also said that they had to pull start it before I bought it because it had not been ridden in quite a while which I believe becase of the spider webs on the knobbies. I repaired the damage and all is good. I have rode the quad out in front of my house on pavement and it seemed to check out good, running and shiftine fine. I decided to change the oil and pull the drain plug and find part of a gear tooth stuck to it. I pull the starter cover and check the gears and they are OK. I havn't pulled the clutch cover yet but planning on doing so soon. Does any one have a idea of a weak area (hopefully under clutch cover). I am thinking the damaged may have been from pull starting the quad but really dont know. The tooth is about 3/8 of an inch wide across the face and the section I have is about 3/16 of an inch tall. I am hoping it came off of the gear on clutch basket. The quad does seam to run and shift great other than that. is there any place to inspect tranny gears, through drain plug hole or return hole in clutch side cover?Any input appreciated.

 

Unfortunately there arent any weak areas that I know of in the Ds gear wise. Can you post a pic of the piece. The only visual access for the tranny is through the hole in the cases that the cylinder slides in to.

 

Pull the clutch cover and inspect the gears of the actuator on the inside that is connected to the clutch cable. I had a couple of these teeth sheer off of my 04 after installing stiffer clutch springs. I believe BRP had a bad batch of these around 04/05 time frame. You will need to drain the oil prior or tip the quad on its side to keep the oil from running out when you pull the clutch cover. Let us know what you find.

 

Thanks for the replies, hopefully I can get to it this weekend.

 

Yep, what DSengineer said. I think, and hope, that that is where you find your problem. I run 80% springs and have had teeth on both the actuator and the clutch release shaft shear off. They will break on the shaft alot quicker than they break on the actuator itself. Quick easy fix for both, but no parts on a DS are cheap.
Good luck and keep us posted.

 

I pulled the clutch cover and inspected the gears on the clutch and they were ok. I then inspected the primary gear that drives the clutch and timing chain and there is where the broken tooth was missing. About the top half of it was gone,not enough to cause it to slip but would have caused trouble soon. Now for the bad news, I looked at the parts deagram and the gears are sold as a set and over 350.00. Ouch. There is no wear at all on the gears other than the broken tooth.Do I need to replace them as a set? Does anyone know where I can find a primary gear by itself? Already checked ebay and didnt see any. Thanks for the help so far just need a little more.

 

There are 2 on Ebay right now for 10.00