Metal shavings in crankcase of Baja Storm 125

[Adrian Ciotinga]

The title pretty much explains it all. When using the starter I can hear it spinning but not engaging the engine. The wheels also do not engage with the wheels when the clutch is out. The motor has compression if that helps.

I am new to engine work and repair and I bought this quad with the idea of fixing it up (not knowing the full extent of the damage). The previous owner said it ran but sat for a year (I don’t believe that for a second after opening it up) and had bought a few new plugs and a starter motor, none of which fixed the issue.

Any help would be greatly appreciated!

I have attached a few pics of what I think could be wrong.

[Ajmboy]

So when in gear and you let go of the clutch its like its in neutral and noting happens? Are you using the pull start to crank it? Aren't those semi auto or do they actually have a clutch?

[Adrian Ciotinga]

Yes. When I push the quad with or without the clutch there is no engine resistance. This type of quad has a CVT so there might be something I am missing. There is no pull start (only electric). Thanks for the reply.

Oh and I am cranking it with a wrench.

[Frank Angerano]

As long as it’s in neutral it should not have resistance with or without the clutch.  So if you put it in first gear or any gear for that matter the engine should resist with the clutch out and very little resistance with it pulled in.  So first I would go through all the gears one by one and see that it’s changing gears properly. After that I would look at the clutch actuator that expands the clutch. It’s the lever on the side of the engine where the clutch cable connects to.  There is a shaft back there and that rolls the clutch out. Based on the metal chunks it sounds like you maybe blew a gear.   

[Adrian Ciotinga]

As I stated previously the quad is equipped with a CVT and does not have gears to run through. Also the starter is not connected and when I crank the engine the large gear on the crankshaft that is connected to the starter gears slips past the shaft. Is that normal?

[Frank Angerano]

Your not being clear ! Does the bike have a clutch lever ????? 

I don’t think that bike has a clutch lever but your saying yes so be clear on what your saying and we can help.  

[Adrian Ciotinga]

The quad has a clutch and a CVT. The clutch does not appear to do anything as the engine does not seem to be connected to the wheels regardless of whether the clutch is pulled in or not.

The clutch is only for starting and stopping, not for running through any gears.

[Frank Angerano]

How does the lever feel when you pull it in? There should be a spring loaded type pressure.   If so and you can see the clutch expands on pulling the lever then it’s working. It’s most likely something internal. Maybe a shaft or gear and will involve pulling the flywheel and exposing as much as you can without splitting the engine.  If not then your going to have to yank the engine. 

But before you do all that. Have you checked the drivetrain to see that any of the drive shafts and yolks are not broken including the rear differential? 

Start with the simple stuff first before you go deep.  

[Adrian Ciotinga]

26 minutes ago, Frank Angerano said:

 

As I said before I am new to this kind of stuff and completely failed to notice the clutch cylinder. Would this result in the clutch not disengaging?

Thank you for your reply.

[Adrian Ciotinga]

Just something I forgot to add:

The clutch still has resistance and springs back after I release it, hence the reason I did not suspect a problem with it. 

[Frank Angerano]

That’s not a clutch!!!!!!!!!!

But like you said new to this you are.  That’s a break cylinder. And that’s a break lever. 

I knew you were not explaining it correctly. 

 

[Adrian Ciotinga]

I am totally confused now. If the quad does not have a clutch then why do the wheels not connect to the engine? And how could I bump start it?

Back to the starter not engaging I believe the thing that I took a picture of in the second to last image is shearing off (if not completely gone already). Could that be the cause of my issues?

Thanks a lot for your help.

[Frank Angerano]

You can’t bump start a centrifugal clutch.  It works on expansion and revolutions. The faster it spins the weights in the clutch expand grabbing the housing and the wheels spin.   

Im not 100% familiar with your engine without looking at a manual as well as the angle of the pics you sent but if you removed the clutch off of that shaft and your seeing shear marks I would guess that’s your problem.   

[Adrian Ciotinga]

Just before I go tearing things apart with no idea how to put them back is the clutch the large grey disk visible in the first photo?

[Frank Angerano]

What came off of that shaft ? 

Post a few more pics of the engine maybe from a little further out. It’s hard to make out where your taking the pic from. 

[Adrian Ciotinga]

I hope these new photos are good enough. All of them come from the right side of the quad with the transmission on the left.

[Frank Angerano]

So based on the pics it looks like something was taken off of the shaft in the pic? Is that correct.

On the other side of the engine, is there a cover that’s much different ? the clutch assembly is generally bigger and it’s a  larger size cover. Like I said I’m not familiar with that engine but the premise is pretty much the same as other engines.  

I’m just wondering if you have taken anything off.   

Is that the left side of the engine your showing ?

[Adrian Ciotinga]

I did take off a gear and the flywheel from the shaft in the pictures above. The left side is very different from the right side in appearance and size. Thank you for all of your help today but it is getting quite late where I am and it is difficult to see with my dim garage lights. I will continue working tomorrow.

Here is a picture of the left side of the quad. I believe it hosts the CVT as the end of the cover leads to the chain that turns the wheels.

[Frank Angerano]

That’s the cover you want to pull if you want to see what’s going on with the clutch.  

[Ajmboy]

@Frank Angerano great help here, could not have explained it any better! 

@Adrian Ciotinga pull that cover off and see what's going on, then post some pics. 

[Frank Angerano]

So when you get back to work on the bike you can test a few things.  

1. Bump the starter button and see if that gear coming from the starter spins.  If so then you may have just lost the keyway that holds the flywheel and starter gear on the shaft  or the nut came loose holding the flywheel. Not likely but possibly.

2. That break lever your referring to when you say you need it to start the bike has a pin that’s sticking up to lock the brake. The reason you thought it was a clutch I’m assuming is because you cant start the bike without pulling it in.  That’s just a safety in place so god forbid the throttle got stuck and the bike started it would take off. This brake safety stops that from happening.  

The side cover with the clutch inside can be taken off and inspected and we will help you walk through the process.  Just take care of the starter problem first.  

 

[Adrian Ciotinga]

I don’t know what happens when I use the electric starter but when I crank the engine with a wrench the gear on the crankshaft connected to the gear on the starter slips and does not engage the crank. Are you sure that using the electric starter when the cover is off and without oil will not damage the engine.

[Adrian Ciotinga]

I found a digital owner’s manual and discovered that the quad is in fact a 150 and not a 125 like I thought initially. Not sure what good this does but just putting it out there.

http://www.bajamotorsports.com/system/documents/126_OWNERS_MANUAL_-_BA150_14_yr_Owners_Manual_VIN_prefix_LLC_.pdf

[Frank Angerano]

Well it’s a good manual for maintenance. Not repairs.   Any luck with pulling the clutch cover or getting into the starter issue?

[Adrian Ciotinga]

I don’t know what happens when I use the electric starter but when I crank the engine with a wrench the gear on the crankshaft connected to the gear on the starter slips and does not engage the crank. Are you sure that using the electric starter when the cover is off and without oil will not damage the engine.

[Frank Angerano]

You don’t want to continually crank the starter over and over and for long periods of time.  I would pull the starter out and see what’s going on. It may be a busted shaft or whatever but pull the starter out and see what’s happening.  

[Adrian Ciotinga]

I know for a fact that the starter itself works as I tested it before installing it. What should be my next course of action?

[Frank Angerano]

And when you press the starter the crank does not spin ? 

[Adrian Ciotinga]

No it does. not

[Frank Angerano]

Sorry brother I was working.  I would have to look at the repair manual to see exactly what’s going on but my guess is that your going to have to pull the starter out and see if everything is in tact and not broken. If that all checks out good then your starter clutch/bendix is bad.  eBay prob would have one.