Kick start assembly

agn5009
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agn5009
Edited Date/Time 4/13/2017 10:36am
What would cause this to happen? I kicked the bike once and this happened. Also, any recommendations where to get the parts? Seems like an expensive fix. Bike is a 2011 yz250.





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F150Motocrosser 3/24/2017 5:51pm
3/24/2017 5:51pm
Ouuchhh!

Here's a replacement inner clutch cover: http://www.ebay.com/itm/2010-2011-2012-2013-Yamaha-Yz250f-Yz-250f-Right…

Complete kickstarter shaft.. http://www.ebay.com/itm/2007-2011-YAMAHA-YZ250F-KICK-START-SHAFT-GEAR-5…

From my experience, you'll need a clutch basket tool to remove the clutch basket in order to remove/replace the inner clutch cover housing.

As to WHY it happened??? The shaft appears to of come untrue / unseated / unmeshed, and grenaded against the cover housing under the awkward stress.. Not sure what would've caused that to happen though. Good luck with the fix.
agn5009
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agn5009 3/24/2017 7:30pm
3/24/2017 7:30pm Edited Date/Time 3/24/2017 7:32pm
F150Motocrosser wrote:
Ouuchhh! Here's a replacement inner clutch cover: http://www.ebay.com/itm/2010-2011-2012-2013-Yamaha-Yz250f-Yz-250f-Right-Crankcase-Inner-Clutch-Cover-/162437460276?hash=item25d206f134:g:dtEAAOSwgZ1Xr9mJ&vxp=mtr Complete kickstarter shaft.. http://www.ebay.com/itm/2007-2011-YAMAHA-YZ250F-KICK-START-SHAFT-GEAR-5NL-15601-20-00-2007-2013-WR250F-/262269096637?hash=item3d1074d2bd:g:8j8AAOSwKtlWrgKk&vxp=mtr From my experience, you'll need a clutch basket tool to remove the clutch basket...
Ouuchhh!

Here's a replacement inner clutch cover: http://www.ebay.com/itm/2010-2011-2012-2013-Yamaha-Yz250f-Yz-250f-Right…

Complete kickstarter shaft.. http://www.ebay.com/itm/2007-2011-YAMAHA-YZ250F-KICK-START-SHAFT-GEAR-5…

From my experience, you'll need a clutch basket tool to remove the clutch basket in order to remove/replace the inner clutch cover housing.

As to WHY it happened??? The shaft appears to of come untrue / unseated / unmeshed, and grenaded against the cover housing under the awkward stress.. Not sure what would've caused that to happen though. Good luck with the fix.
Awesome thank you so much! That's not as bad of a fix as I thought if that's all I need. I thought about having the case welded, but for that price I would just buy that one.

Edit, crap those links are for a yz250F. I actually have a yz250 2 stroke.
F150Motocrosser 3/25/2017 10:10am
3/25/2017 10:10am
agn5009 wrote:
Awesome thank you so much! That's not as bad of a fix as I thought if that's all I need. I thought about having the case...
Awesome thank you so much! That's not as bad of a fix as I thought if that's all I need. I thought about having the case welded, but for that price I would just buy that one.

Edit, crap those links are for a yz250F. I actually have a yz250 2 stroke.
Ah shit, you're right... My bad.. Here's the right parts... I'm sure you can find them cheaper second hand..

Kickstart assembly: http://www.ebay.com/itm/5NX156011000-KICK-SHAFT-ASSY-/282255312441?hash…

Parts drawing for the kicker: http://www.yamahapartshouse.com/oemparts/a/yam/5004d6eff87002275461d6e8…

Inner clutch cover / "crank case cover 3" as they call it: http://www.ebay.com/itm/Yamaha-5NX-15431-00-00-5NX-15431-00-00-COVER-CR…

Prats drawing: http://www.yamahapartshouse.com/oemparts/a/yam/5004d6eff87002275461d6e7…

Looks like there's a good 4-5yr span at least where that engine casing is compatible. I'm a KTM guy so I don't know YZ engine eras.
F150Motocrosser 3/25/2017 10:15am
3/25/2017 10:15am
How certain are you that the kicker lever was on there nice and tight? Ever have it off the bike / notice the splines were getting spooged up? How tight is the bolt that holds the kicker into the shaft?? The kicker lever somehow getting squirrelly is the only thing I can think of that would've allowed for such awkward stress on the shaft/case when you went to kick it. Were you kicking it nice and square, or was your boot on the outer edger of the kicker and maybe not coming straight down in the most ideal "stroke" ?? Just thinking out loud here...

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pCp 252
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pCp 252 3/25/2017 1:18pm
3/25/2017 1:18pm
I bought an 07 YZ250 and the kickstart shaft was broken just like this. However the case was fine. While researching a fix, it was apparent this is pretty common thing to happen for this bike. I picked up a used 2010 YZ250F kickstart shaft assembly and although the part numbers varied slightly, it was identical to the broken 2 stroke counterpart.
Hugh_Falwell
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Hugh_Falwell 3/25/2017 1:43pm
3/25/2017 1:43pm
My 04 yz 450 did the same thing, what are the dimensions of your kickstart shaft? Trying to see what all swaps out as I don't want to buy the 04 450 one for $200
combatmx
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combatmx 4/12/2017 2:03pm
4/12/2017 2:03pm
Wow i just bought a 2017 yz 250 and had to kick it more then once and it felt like it stripped kick starter gears or the clutch basket gear the bike might have 4 hours since I picked it up at the dealer.I can believe you broke the cases that's yam ha saveing money.I'm not sure what to do deal with it till I can't start it or take it apart and see what corner that cut well I hope you get it fixed
kijen
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kijen 4/12/2017 3:08pm
4/12/2017 3:08pm
I think going back to a 2001 yz250 shaft is thicker, and same year clutch case. All fits. I used a old 426 Kickstart too.
Aceofspades 4/13/2017 10:36am
4/13/2017 10:36am
My old 2000 kx250 stripped numerous kick shafts and was tiny. I did research and found a 2010 kx450 kick shaft and kickstart knuckle fit as long as i used an 93 clutch case,and was twice the diameter and beefy as hell. Id wager a yz400-450 shaft and knickle would fit but youll have to study a little on it.
Aceofspades 4/13/2017 10:36am
4/13/2017 10:36am
My old 2000 kx250 stripped numerous kick shafts and was tiny. I did research and found a 2010 kx450 kick shaft and kickstart knuckle fit as long as i used an 03 clutch case,and was twice the diameter and beefy as hell. Id wager a yz400-450 shaft and knickle would fit but youll have to study a little on it.

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