Hi Guys,

Well I just finished a installing a new top and bottom end on my sons 2005 eton 90 (W/O Reverse). After reinstalling the starter components (Big Plate Washer, Starter Gear, Needle Bearing, Starter Clutch Assembly,Variator, The Aluminium Cylinder, the Fan and finally the washer and kickstart gear.

What I do notice is that when I only hand tighten the nut I can get the bike started via the electric start. Once I take my impact and tight down the nut, the fan presses inward to the belt and thats when I cannot move the assembly at all.

Am I missing something. I look at the parts diagram on the website "anything atv" it shows I am missing Part #3 "Boss Gear", whatever that does

Thanks for the help in advance guys.

 

Now I am thinking that the replacement crank I got to do the bottom end might need a little grinding as it protudes very little past the kickstart gear and I know that should not be. Maybe that is why when I tighten down the variator nut with the impact I can literally see the fan pulley get pushed back into the belt and thus pushes everything else (Starter Clutch, Starter Gear) back againest case wall.

Does that make sense guys? Being that it is a used Crank. If it is installed correctly the variator nut washer should stop when the crank splines begin and the variator nut would not push on the crank splines forcing everything back.

Sorry guys for the continued questions, but I am learning quite a bit about these miniatvs on this website.

Thank you

 

Are you pinching the belt in the variator? When you tighten the nut on the variator you need to kinda hold the belt up on the ramps so that doesn't happen.

 

Hi,

Yes I made sure the belt was not pinched. I just cant understand. Here is how exactly I installed everything. Am I missing something? Could the crank be slightly longer than the original?