1997-2001 Honda CR250 Kickstarter Maintenance Part 2: Inspection

Fix Your Dirt Bike

Dec 26, 2016

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!

1997-2001 Honda CR250 Kickstarter Inspection

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 replaced.
- Kickstarter lever splines
- Ratchet splines
- Bore
- Spring mounting hole
Step 18: Measure the idle gear bushing inside and outside diameter.
- Outside Service Limit: 19.96mm
- Inside Service Limit: 17.04mm
Step 19: Measure the idle gear bore.
- Service Limit: 20.07mm
Step 20: Measure pinion gear bore.
- Service Limit: 20.05mm
Step 21: Assemble your 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.