Posts
4
Joined
11/7/2024
Location
Goshen, CT
US
Hello i am a new rider and I bought this bike recently. After rebuilding the top end and bottom end, i am just stumped by the bike, it won’t kickstart. I removed the clutch plates and kept the clutch basket attached, but the bike won’t kick over. If I remove the clutch basket, the Kickstarter works fine. I can turn the bike over with a wrench on the timing chain side and the final drive gear side. But can’t figure this out.
Make sure your clutch basket is fully seated and meshing correctly with the primary drive gear behind it.
I did check that, i can turn the motor over with the clutch basket installed with a wrench, but I can’t kick it. Its starting to drive me crazy lol. Have been at this all day…
Then perhaps it's isolated to the Kickstart gear? Double check that. There's only so many things it could be.
I thought it was that but i think its fine… all the manual says is after installing the gear to pull the spring 180 degrees to put it into its holder. Like the Kickstarter works perfectly fine without the clutch basket installed, but even with the clutch installed, I can turn the whole system over wrench. But now after drowning the insides of the bike in assembly lube, i can get it to partly kick over. Like a 1/4th turn and then nothing after that. Just locks up. I thought maybe timing or something with the timing chain that but I double checked it. And its all in specs.
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Indeed sounds like the gear is not meshing properly with the idler gear when you go to kick it. Is everything assembled like the parts diagram below? Are you testing it with the crank cover installed?
https://www.motorcyclespareparts.eu/en/kawasaki-parts/2005-kx250f-off-road/kick-start-mechanism?_gl=1*1ep4bum*_up*MQ..*_ga*MTE0OTY4NjAwOS4xNzMxMDU5ODQ2*_ga_EPD8J02JH6*MTczMTA1OTg0NS4xLjAuMTczMTA1OTg0NS4wLjAuMA..*_ga_6BMCJMKCL9*MTczMTA1OTg0NS4xLjAuMTczMTA1OTg0NS4wLjAuMA..
So I disassembled everything and reassembled everything on that side of the case. Now i got it to kick over but every few times it will just stop almost at bottom and be really difficult to finish the kick. Like i am having more trouble with this then i ever expected. I would take it to a bike shop. But non of them want to work on this thing because its a 4 stroke, its truly disheartening.
So you've disassembled and reassembled and made some progress. Start looking REALLY close at the items you touched. Take the inner clutch cover off again, slap the kickstart lever back on, remove spark plug and slowly rotate Kickstart lever as you watch every piece you've touched. Frustrating, but should be fairly simple to inspect if you just take it slow. Something is obviously binding.
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