This is Part 2 of the step-by-step Kickstarter maintenance for your 1997-2001 Honda CR250 Dirt Bike.
You can find Part 1: Removal here, and Part 3: Installation here.
You Can Get Parts And Tools Through Our Partner Links HERE!
Follow along with the video below!
1997-2001 Honda CR250 Kickstarter Inspection
Click The Pictures To Start Slideshow!
|Step 9: On a clean, flat surface, disassemble the kickstarter assembly.|| |
|Step 10: The snap ring retains the interior thrust washer.|
If the snap ring is tight, DO NOT remove it. However, if
the snap ring is even slightly loose; it needs to be replaced.
|Step 11: Inspect the return spring for tension, unusual|
bends, breaks, or any signs of excessive wear.
|Step 12: Inspect the ratchet spring for the same issues.|
This spring is light and is meant to be compressed to
under 1/4 inch when installed.
|Step 13: Inspect the ratchet inner splines, ratchet|
teeth, and stopper arm.
|Step 14: Check the pinion gear for a smooth bore,|
straight gear teeth and ratchet teeth.
|Step 15: Inspect the collar. The collar keeps the return|
spring in place. Check for wear around the opening and exterior.
|Step 16: Make sure the exterior thrust washer is|
still flat and smooth.
|Step 17: Inspect the following parts of the spindle.|
If any of the following parts are worn out the spindle needs to be
- Kickstarter lever splines
- Ratchet splines
- Spring mounting hole
|Step 18: Measure the idle gear bushing inside and|
- Outside Service Limit: 19.96mm
- Inside Service Limit: 17.04mm
|Step 19: Measure the idle gear bore.|
|Step 20: Measure pinion gear bore.|
|Step 21: Assemble the kickstarter.|
- The punch on the bore and the punch on the ratchet
need to line up.
- The ratchet spring will sit loosely around the ratchet.
|Step 22: Check the pinion bore in the crankcase for|
smoothness, and the ratchet stopper breakage.
|Step 23: Measure the countershaft.|
If you have any questions or anything to add, please leave them in the comments or on our FaceBook page!
97-01 Honda CR250 Kickstarter Part 3: Installation →
Keep Your ’97-’01 CR250 Running Right!