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post #1 of 7 Old 03-13-2008, 06:39 PM Thread Starter
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Any dirt bike mechanics here?

Hey guys. I've got an old 1986 CR250 in mint condition. I rebuilt the engine over the fall/winter. All seemed to have gone well until now. My kickstarter is slipping BADLY. I was wondering if there are any particular parts I should be looking at. I don't think the gears themselves are a problem as they were fine before I tore everything down. I must have done something to it. Thanks for any suggestions.
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post #2 of 7 Old 03-13-2008, 06:42 PM
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i believe there is a gear that extends out in the gear box as you kick the lever down. is that moving like it should?? it may not be engaging properly.

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post #3 of 7 Old 03-13-2008, 06:43 PM
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Define how or what is slipping?

2003 F-250 CC 4x4 SB 6.0
Custom 03 Turbo, WPE Intake,
HD 97 Fan Clutch, MBRP Y Pipe,
Scangauge II Rancho 9000XL,
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post #4 of 7 Old 03-13-2008, 06:43 PM
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Are the splines chewed up on the shaft coming out of the case cover. If so you may need to replace that shaft. Or is it slipping inside the case cover.


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post #5 of 7 Old 03-13-2008, 07:22 PM Thread Starter
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It is slipping inside the case cover. It feels like it wants to catch but won't under the pressure of a big kick. I am wondering if I shouldn't try a new spring. I think no matter what I am going to have to take the clutch plates out AGAIN and see what I can find.
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post #6 of 7 Old 03-13-2008, 07:25 PM
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It sounds like you don't tension on the spring of the kickstart. I would remove the case cover. Check the spring to make sure it is installed correctly.


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post #7 of 7 Old 03-27-2008, 05:21 PM Thread Starter
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Well, Bigcountry, you were pretty close. I found a blown up drawing of the kickstarter mechanism and I found that there was a thrust washer missing. I must have lost it during the teardown. The washer holds the spring to build up the tension. So all my frustration was probably caused by a washer that is worth $4.83, if ordered. A local bike dealer found one for me that is very similar and didn't even charge me. Damn bikes. I love the stupid things but it is tempting to throw them into a lake at times.
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