bubba2
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help !!hello can anyone help tried to start my kh250 yesterday and clunk it went . i have no longer a kickstart except on the return spring !! have i got to take the motor back out 
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simonh
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depends, take the clutch cover off and just near the kickstart shaft is a big bolt, its the kickstart stopper, undo that (its fooking tight!)then you should be able to wind the kickstart mechanism.
If that dont work one of two things has happened, you forgot to align the kickstart tang inbetween the cases or its snapped - take out and repair 
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The Wolfman
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So the kickstart doesn't spin the motor on the kick stroke but springs back OK, is that correct?
Does the clutch work as it should (try rolling the bike and engaging 1st)?
if the answer to both those questions is 'yes' then you will have to remove and split the engine by the looks of it.
If the clutch is playing up then you might get away with just the right hand cover coming off.
Either way, that's a bummer for something as simple as that.
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bubba2
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help !!Cheers chaps tried all above and you both confirmed what i thought !! think spring might have snapped been kicking it over loads and there was not a lot of stroke to start it . can the job be done from upside down or have barrels got to come off !! 
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The Wolfman
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You can leave the whole top end in place to split the engine, but the engine is usually split upside down on the bench.
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bubba2
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help !!Thanks looks like i'll be in the shed for a while .so close but so far !! 
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bubba2
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help !!Well lads it was a kickstarter pinion holder little fecker was in half !!
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simonh
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Re: help !! | bubba2 wrote: | | Well lads it was a kickstarter pinion holder little fecker was in half !! |
i'e got some complete kickstart assemblies on my bench that i just found in my parts box 
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bubba2
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help !!Simon think we are chasing each other around the site. A chap called dave has put a pic on parts wanted under same heading looks like he has had same problemo as me .. 
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simonh
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aha  i've never managed to break one of them maybe its metal fatigue or user error on reassembly 
i've got a complete assembly, simon (g6mow) may have just that bit
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bubba2
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help !!Evening chaps think my spring was a bit weak anyway. could only get any bite on the last third of the kickstart !! how do you want me to pay for the pinion holder simon..
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180kid
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found a few bent springs in there rather than broke ones, thinks thats the prob.//. and you must get that tension right, its all in the haynes,...
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simonh
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i'll have a look on friday for you
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