Hi all, I have a 2003 rev3 250. Whilst cleaning and greasing the kickstart ball bearing and spring the other day, I noticed a small amount of "slop" in the splines for the kickstart. The securing bolt is tight so i guess its just the splines wearing down. Is it possible to buy just the splined part or do I need to buy a complete kickstart assembly which is quite expensive? There is only a small amount of play but these things have a habbit of getting progressively worse untill they fail , or is it normal?? Has anyone else had this problem and just left it?

Cheers Mike

what happened on mine was the weld on the washer of the steel part of the kickstart had cracked causing the slop.

so basically the kickstart was free to move on the spline and only the washer was holding it roughly in position.

have a check whether the washer is still welded properly to the other part.

what happened on mine was the weld on the washer of the steel part of the kickstart had cracked causing the slop.

so basically the kickstart was free to move on the spline and only the washer was holding it roughly in position.

have a check whether the washer is still welded properly to the other part.

Same. Short run of weld sorted mine out.

Thanks for that guys, i'll have a look at that tomorrow.

My Rev 3 is the same, It has been like it since July 2006 when I got it new. It fits tight on the spline but the centre seems loose even with the outer nut tight.

Had a look today and you were right the weld has cracked. What a s**t design!! I'll have to try and get someone to weld it for me.

Thanks for the pointers, much appreciated.

Cheers Mike