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200 exc Kickstarter Issues After Rebuild

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Wondering if anyone else has had this issue, I have the factory manual and installed as to how it instructs. The issue I'm having is when I put the cover on, when i tighten (even snug) the bolts right around the kickstarter, it wont return on its own to the resting poistion. It spins the motor over fine, and i can return it to the resting position and it stays, it just doesnt return on its own. When I kick the motor, or "kick it" by hand, it just stays in the down position.

 

The last time I pulled the whole side apart, removed, inspected and re-installed, I didn't find anything out of place. It feels perfect right up until I snug the bolts down for the cover.

 

I have tried a little oil on the o-ring, made sure that the new seal was seated fully, installed with and without washers for the kickstarter, anything I could think of, and nothing has made much of a difference.

 

I just rebuilt the engine, and it fires up and runs great, no weird noises from that area or anywhere else for that matter.

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It has enough tension to return normally, until the bolts are tightened.

I tried to spin it around again and it deformed the spring and the cover wouldnt fit anymore.

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maybe you have other issues but after checking the parts pic if all looks well try getting some 050/060 gasket paper trace out your gasket snip it and then give it a go?

I have come across a few cr250 motors that where sensitive to gasket thicknes

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Yeah I coat the entire trans with oil before assembling. I tried some oil just to be certain and it made no change. It works perfect right up until the side case is tightened. If I crack the 3 or 4 bolts around it with the rest of the case snug, it works fine.

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maybe you have other issues but after checking the parts pic if all looks well try getting some 050/060 gasket paper trace out your gasket snip it and then give it a go?

I have come across a few cr250 motors that where sensitive to gasket thicknes

gasket paper is cheap at the auto parts store

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I got a OEM ktm gasket on the way just to be sure it is the correct one. I'm lazy and suck at cutting new gaskets haha

 

Will update when I get some time to try it.

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I got a OEM ktm gasket on the way just to be sure it is the correct one. I'm lazy and suck at cutting new gaskets haha

 

Will update when I get some time to try it.

 

Either its too little clearance or wrong spring tension.

 

My Suzuki RGV250 was a POS to get tensioned correctly, the spring would slip each time I put the case cover on.

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Pulled the covers off again and re-installed the kickstart assembly. New oem ktm gasket. Greased and lubed components on assembly. Tensioned the spring per the manual, it was tough to get right, but I got it.

Put it all back in aaand...still won't return on it's own. If I loosen the three bolts around the kickstart it works fine.

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I have tried a little oil on the o-ring,

What o ring are you talking about?  Water pump? There is no o ring up around the kick start.

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I meant on the seal around kickstart shaft. Greased the shaft where it sits in the case and lube the seal with some oil. No change

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I meant on the seal around kickstart shaft. Greased the shaft where it sits in the case and lube the seal with some oil. No change

Have you taken a look at the exploded parts view and made sure you've got it assembled correctly?sounds like something is off, maybe an extra washer in there or something.
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Yea I did that this time. I had removed a small washer to see if it would help. So put it back in so it was all coorect per the manual

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Yea I did that this time. I had removed a small washer to see if it would help. So put it back in so it was all coorect per the manual

I did mine yesterday and can't think of what you could be doing wrong, it's pretty straight forward.

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