Question about KTM 250 SX Motorcycles

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Hi, i have a 250sx and the kick does no work at all, the kick start and the shaft that its attched to just goes down and up freely. the kick springs back up if that will help you solve this issue. is there some sort of cog to change in the bottom end that wears out. thankyou regards Fred

Posted by fred kazzi on


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The starter pinion attached to the kick pedal has an ratchet pin that engages in the engine shaft - the role of the pin is to allow the engine to turn freely once started. This pin is pressed on the shaft with a simple spring that in your case either broke or went out of position.
You will need to open that side of the transmission, access the starter mechanism and refit or replace the pin and its spring - it's a delicate job, work very carefully or you can do a lot of damage if you try to start the engine with the parts misplaced.

Posted on Sep 25, 2011


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1 Answer

1985 Honda 250SX shifts hard

Hey Jerry,
No, you do not want a lighter spring.. it will cause the engine to start "falling" out of gear, or not staying in gear when you shift... hard shifting is usually a sign of something wrong.. possibly a bent shift shaft, or worn/bent shift forks.
If it is hard to shift, both up and down, in all gears, its more than likely a bent shift shaft..(the shaft the shift lever is bolted to and runs through the center cases to the right side and controls the shift cam.).. You will have to remove the shifter(lever) and the right side cover, the clutch assy, and maybe a couple other small items..IF you are NOT intimately familiar with this repair - Take it to a qualified professional!!!

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Is this a genuine part if not the part may be at fault also if not is there any dirt through the hole in the crank case the gear shaft goes through a simple solution is to use a multi tool and sand the shaft or crank case hole

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Need to change kick start spring

Hi, i am sorry but you dont say what the model of your machine is, this would help me determing the correct, answers for your questions, most kickstart springs can be changed by simply removing the clutch cover followed by the kickstarter shaft and then replacing the spring, make a note of kickstart stop location carefully remove the shaft holding the gears together replace the spring followed by the. Replacing the shaft and tensioning the spring before cover replacment, oil,etc. Some machines the shaft and spring is inside the centre cases and a complete engine strip is ness

Sep 25, 2011 | kawasaki KX 250 Motorcycles

1 Answer

Replacing kick start shaft

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.

Hold WP shaft down with your thumb while pulling on the cover.

Once the cover is off the Kick Start idler gear assembly lifts out easy but as you put it together there is a center punch mark on the gear that goes in first that MUST be in aline with the spring hole drilled into the shaft, if not in aline the starter will engage at the wrong point.

Reinstall new shaft and idler gear in reverse order.

Jun 04, 2011 | 2008 KTM 250 SX-F

1 Answer

I have a kawasakikmx 125 which had a slipping kick start i have removed the engine casing but cannot see where the spring end is meant to locate does anyone have a diagram please thanks Neil

I can't find a diagram of the position of the spring when connected, but I can describe it, the spring has 1 straight end that connects through in the hole in the shaft of the kick start, and a bent one protruding out of the bottom of the spring at a kind of right angle. This one goes into the casing of the engine not the case cover, if you look around the edge of the casing, just below where the kick start assembly goes you should see a hole that holds no purpose. That where the other end of the spring goes, just pop it in and lever the assembly back to position.

May 15, 2010 | 2002 kawasaki KMX 125

1 Answer

My 2001 KTM 250sx is stuck in gear, the shifter moves up and down but does not change the gears. I removed the clutch everything is pefect, gonna pull the basket. Any ideas? I have seen other saying bent...

It sounds like the end of the shifting shaft has broke loose, it is a welded joint, If you can grab the shifter with your hand and feel that thing slip in there, up and down,that might be the problem, but splitting that case, ugh, total rebuild.Too bad you can't get to it through the clutch. Hope this helps.moz-screenshot-1.png

Mar 17, 2010 | 2001 KTM SX 250

1 Answer

I have a bosch 250SX NG. I keep getting an A2

hi and good morning from sunny spain your problem is with your flue gas limiter good be a number of things try these the gasket on the flue gas collector could be dislodged /also check your overheat sensor hope this helps you sort the problem please give me a rating thanks pete

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1 Answer

I was riding my wr 250cc

Check the sprockets. Got a stick or rock binding the chain? Remove the chain. Does the wheel spin freely? Brake frozen?

Since your bike is water cooled, a seized piston is not too likely. Got water in the radiator? Most likely is a broken torsion spring on the kick start shaft. The adjacent ratchet wheel and the kick shaft should be inspected. The ratchet wheel should have a smooth movement. If not then replace it. The kick shaft should not show wear or damage. The same is true for the kick gear and idler gear. Replace as needed.

The only other possibilities are a frozen main bearing, (not likely), a broken or severely bent shift fork, (more likely than a main bearing).

Please rate this solution. Thanks!

Apr 11, 2009 | 2004 Yamaha WR 250 F

1 Answer

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Put the bike in 3rd, 4th or 5th gear, the higher the better. Sit on the bike, with your hand off the clutch lever, and rock the bike back and forth to rotate the clutch hub. This might free up the lever. You will need to drain the oil and remove the right side casing to see and service the kick starter. If I recall correctly, there is a spring clip that allows the kick gear to engage the clutch hub. The piece could be broken, weak or out of position.

Please rate this answer. Thanks Shay!

Apr 06, 2009 | 2002 KTM SX 250

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