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Enduro Engine - 2 stroke Cylinder, Piston, Tranny, Bearings, Clutch, Pipes & Silencers, etc.

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Old 03-28-2009, 07:53 AM
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Default 07 250 Kick Starter

There is some play where the kick starter attaches to the spindle. The bolts are tight but don't prevent the play. There is no slippage around the spindle and the bike starts OK but sooner or later I see a problem that it might. Please look to see how much play your bike may have. If others are tight without play I will probably get new spindle and /or kick starter. I looked at the grooves on each part and they look OK.
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Old 03-28-2009, 08:24 AM
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The shaft has a slight taper in the spline cut, and the starter knuckle should sit a bit less than flush when mounted. If it doesn't, use a shim so that you can tighten the starter back against the taper. When using a KTM starter (they fit too) the fit is a bit sloppy like this and this fix works. I beleive the shim I used was 17mm ID, but check the shaft OD. This may get you by.
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Old 03-28-2009, 10:59 PM
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Default kick lever shim

Had the same problem that i was able to correct today. As GMP stated i cut a small shim approx. 3mm to take up the space between lever body and the shaft end, worked like a charm. also i found that a old wrist pin bearing from a KX250 has the right O.D and I.D. to make a shim from.
you don't have to live on the edge, just know where it is.
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