Measure the cam chain per the FSM to see if it has "stretched" not very common though.

Does the chain try to jump off the gear even with the chain tensioner on? With it off, I noticed mine would do the same thing, but with the chain tight it did not.

Maybe this is a dumb question but did you try resetting the auto chain tensioner first?

 

I believe with the auto tensioner, you have to start and run the engine for it to take up the slack.

 

it should ratchet out as soon as you screw the spring back in. it may extend another tooth or so with the engine running but shouldnt be much. i had zero slack right after installing my auto tensioner back on before i started it up. all i did was spin the motor over by hand a few revs

 

Had a chance to do a little more digging into the engine tonight.. Not good news. 2 teeth on the crankshaft are busted!

 

Oh man that sucks. Never seen that happen before. I believe only Kawi offers a crankshaft.

On second thought you may want to check with Thumper racing. I thought at on time they had a stroker crank. Would make your efforts more worth it.

 

bike bandit lists the crank, but it's spendy.
What do those gears connect too? I would investigate further on all the connecting parts for those gears. The matching gear/component is suspect also.
There is some reason those gears sheared off. I could see one tooth as a metal defect, but 2, no unless the second one let go due to the first failure.

 

No doubt, i see it in ring and pinions all the time. All you need is 1 tooth to let go and it will nuke multiple others from the debris.

I knew that was a bad noise.... just didnt sound right. Sucks about your crank OP, probably cheaper to get a used assembly off ebay.

 

I have a complete engine for sale. PM sent.

 

replied.
sucks but that is the way it goes sometimes! anyone know if an 07 gearcase is the same as an 09?

 

The '09+ has a lower sixth gear ratio.