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 HERE! → https://amzn.to/4h4lDKq
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 it 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: Ensure the exterior thrust washer is still flat and smooth.
- Step 17: Inspect the following parts of the spindle. If any of them 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 the 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.





















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97-01 Honda CR250 Kickstarter Part 3: Installation →
Keep Your ’97-’01 CR250 Running Right!