Question about kawasaki KX 250 Motorcycles

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My 2001 kx250 keeps breaking kick shafts after 15 or 20 kicks. i've replaced the spring, bushing, circlips, washers and now two kick shafts.

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I am not as familiar with kawaski's but a friend told me that certain kx's and yz's had poor quality shafts that were brittle?

the couple of broken shafts that i've seen were caused by the kicker being kicked so aggressively that when it contacts the stop. the stop acts as a fulcrum transferring the load to the shaft thus breaking it and possibly the case to.

Posted on Oct 06, 2009


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Great bike!

To get to the kick starter shaft and idler gear you will first have to remove the kick start and brake levers. Then remove the water pump cover and circlip, the impellor, and steel drive pin. Then remove all side cover bolts and pull the cover off the engine. Don,t let the water pump shaft come out of the engine when you pull of the cover . Suggest the best thing to do is set the engine in TDC with the timing marks on the cam side together. When the shaft come out you have to time it again, so hold it in place in the engine.

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