NEED HELP... Banshee Broke

[SouperSport]

I donno what to do yet... was riding my Shee... parked on a hill to look around and turned the engine off (on purpose of course). When I went to start it, the kickstarter "missed". It will not engage with the clutch and therefore won't turn the engine over...

(Oh it gets worse)

I coasted downhill and poped the clutch...NO PROBLEM... she started right up. Well then it would not shift! AT ALL. I was stuck in second gear. The clutch will disengage when I Pull the clutch lever but it would not shift in or out of gear. I had to drive like 3 or 4 miles home in second gear. There was this slight grinding noice in the CLUTCH case the whole way back. Not really bad, but noticeable. By the time I got home I could shift to first, neutral, and second. But it shifts VERY hard, and in neutral it sounds like the gears are grinding ever so slightly (this sounds like it's in the transmission).

I think it's kinda strange that this happend all at once. Obviously my only re-course is to drain the oil... pull the clutch cover and go from there.

But has anyone else had a similar experience that might help me pinpoint the cause of the problem? (ironically I JUST bought a clymer manual...was hopeing I wouldn't have to use it too soon though) Any suggestions?!?

Oh yeah...it's a 2004, with about 50-60 hrs on it (I think)

[Zilladude]

If it wont kick over & wont shift, I would pull the clutch cover off & inspect for a damaged gear or if something came loose in there. I would definetly recommend getting a service manual if you dont have one.( They are a life saver at times!)

[flotek]

only one way to find out for sure gotta yank the cover off and drain the oil ,i dare not say what i think it is . i cant hardly belive this is a banshee that doesnt happen very often on a yammie, especially that soon!

[bigkahun74]

it can't be good, but you can only start draining the oil and pulling the clutch cover off.
and hope for the best!!!!!

[SouperSport]

I didn't have to wait for ya'll to say so to yank the cover... guess I just wanted some ideas, cause I didn't think I was gonna strip it down very far today...

BUT I did and here's what I found....

Tranny is fine (as far as I can tell), I removed the "debris" and it shifts no problem..

DEBRIS?!?!? WHAT DEBRIS?!?

Well, it's call the starter gear! The small one just behind the clutch basket.... well it SHATTERED!! OK, it's only about 5 pieces, but that's shatterred to me! And it caused some damage when it did...

One Tooth broke off of the kickstarted gear... idle gear seems to be fine. Primary driven gear is just fine, but in the process of the starter gear breaking up and falling to the bottom of the case, it scored up the back of the clutch housing (basket), meaning it'll need to be replaced anyway. The screws on the bearing stopper plate are thrashed (screws are not a big deal though) and the little "guard plate" above that is scored up a little, but not completely mutilated. And as you can imagine there was quite a bit of metal filings in the oil and left in the case when I drained it. That's gonna be a mother to clean up!!!

Not bad for a Banshee that's barely 6 months old HUH?!?!?

So I'll need to completly replace the following:
Clutch basket
Starter gear
kickstarter gear
a couple screws

That's at first inspection... I really need to look more closely and make sure everything else is fine before I try to reassemble. If anyone can help with those parts, please PM me... My Banshee is down until then....

[91LT250R]

I'm sure nobody needed to tell you this, but you shouldn't have driven the Banshee home when it wouldn't shift out of second and you started hearing a grinding noise. Grinding noises almost always cost you money and the price goes up with each second of the grinding noise.

Anyway, it sucks that you just ordered other parts and now this happened. It won't be a cheap repair seeing as how a basket will run you about $200 all by itself.

[flotek]

pe basket 130$
other shit not sure gonna have to call to know for sure ,
that really sucks ballz , good thing banshee trannys are very hard to destroy

[SouperSport]

Originally Posted by 91LT250R

I'm sure nobody needed to tell you this, but you shouldn't have driven the Banshee home when it wouldn't shift out of second and you started hearing a grinding noise. Grinding noises almost always cost you money and the price goes up with each second of the grinding noise.

Anyway, it sucks that you just ordered other parts and now this happened. It won't be a cheap repair seeing as how a basket will run you about $200 all by itself.

You're right... you don't have to tell me... but not like I had much choice. It is of course an ATV (ALL TERRAIN VEHICLE), and well.... I was in an area not easily accessible even by a 4X4! Very rocky winding hill! I wouldn't want to drive ANYHING up there. I barely wanted to drive my Shee up there, but I was dumb enough to try it anyway! So I didn't have much choice but to drive it home... so I just kept the RPMs down and coasted whenever possible. From the way it broke and the looks of the other items... I don't see how I could have prevented any more damage. Yeah and I don't expect it to be real cheap... but I'll see what I can do!

[370banshee]

well man it's time to step up to a billet basket... contact wade (flattrack) about the parts you need... i'm not sure that i have anything you need... sorry.... the only baskets around my shop are trashed...

[SouperSport]

I read in the shop manual that the primary drive gear (on the crank) and the primary DRIVEN gear (large gear on the clutch) are matched sets and the "gear lash numbers must be maintained". Does this mean I'll need to replace both gears at the same time (basket & drive gear) to make sure they match or just check clearances (gear lash)?