Question about KTM 250 SX Motorcycles
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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Sep 10, 2017 | ATVs
Sep 25, 2011 | kawasaki KX 250 Motorcycles
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.
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