damn kick starter spring

[skid jackson]

so I have to replace this thing on my 11 250 ....
I won't get into why this is still an issue .....
my question is I have to pull the clutch basket
I don't have a clutch basket tool, or air gun, or welder to make my own tool ....
can I use a piston stop to keep things from moving
or do I have to go buy a clutch tool

part 2
my kicker engages about halfway through the stroke. its an irritatingly small range of "power", my 06 300 had a full stroke. is this lack of kick stroke something new or is it the result of a few skips of the engagement gear and when I open it up I'll be able to reset it and get the full kick again??

[gasgasman]

1) Go rent an electric impact wrench. Buzz that nut right off.

2) Yes. If you "time" the parts correctly.

[Jkosmo]

My 08' EC250 does this same thing as well. I bought the bike used so I wasn't sure if it was a quirk of the bike or something worn out.

I plan on pulling it apart to see if it needs any new parts. Can it normally be fixed by "re-timing", or is it due to worn parts? I was planning on replacing the ratchet pinion, starter pinion and spring this winter but if its simply an alignment issue I'd skip the new parts.

[Jakobi]

When the dealer replaced my kick start shaft this happened to mine. They took it back and retensioned it properly and its been good since!

[ditezz]

You may be able to place a 5c piece(Aussie coin but any small thin ,soft metal coin or brass washer may do) in between the clutch basket gear and the crankshaft gear to hold the basket still .I have used this method before with success

[GMP]

This kind of stuff is what really gets me about GG and causes a step back for every two foward. Its been going on for years now! Weak springs/soft gears. Maybe a little tighter specs and tests on the vendors parts? Duh....

[mcnut]

You can also use a shop rag to jam up the gears temporarily.

[GMP]

The clutch hub is not that tight, and is a standard (CW) thread. My 3/8" drive pneumatic takes them off without any additional retention, so an average electric will do as well. Primary pinion(CCW thread) is another matter, but you need not go there.

[troffer88]

I have poked a piece of rope down the spark plug hole, turn the clutch a little then you can take it off with a ratchet.

Originally Posted by GMP

The clutch hub is not that tight, and is a standard (CW) thread. My 3/8" drive pneumatic takes them off without any additional retention, so an average electric will do as well. Primary pinion(CCW thread) is another matter, but you need not go there.