FBRT95 Posted April 22, 2022 Report Share Posted April 22, 2022 hello together, i´ve got a slight problem with my winter project, a txt 250 2003 (so already the newer engine). i´ve assembled everything and once i push the kickstarter all the way it locks when it should return back in it´s neutral position. when i take out the clutch basket and push the kickstarter it works just fine. in the video you can see how the two gears get stuck with eachother. i already disassambled the the kickstarting mechanism and checked everything and it looks just fine. does anyone know what could cause this problem? thanks a lot! Daniel Quote Link to comment Share on other sites More sharing options...
FBRT95 Posted April 22, 2022 Author Report Share Posted April 22, 2022 Heres the link to the Video https://youtube.com/shorts/RV3G9I3Qigw?feature=share Quote Link to comment Share on other sites More sharing options...
stevec Posted April 22, 2022 Report Share Posted April 22, 2022 It's difficult to see in the video but are you missing the outer circlip on the starter shaft? Here's a Jim Snell video that covers the "Pro": https://www.youtube.com/watch?v=h7disOibvEU . I'm not sure if it's the exact same bike but it may help. Quote Link to comment Share on other sites More sharing options...
faussy Posted April 22, 2022 Report Share Posted April 22, 2022 You need to hold the outer spring and stop it rotating, it helps push the gear back in. Usually the clutch cover is holding it in position Quote Link to comment Share on other sites More sharing options...
reggie Posted April 22, 2022 Report Share Posted April 22, 2022 Perhaps the friction spring MT280226006 is not moving freely in the clutch cover Quote Link to comment Share on other sites More sharing options...
lineaway Posted April 22, 2022 Report Share Posted April 22, 2022 It will never work correctly without the outer cover on. It has popped out of were it sits like in a hole and you have probably stressed the spring out of shape. I have had this issue several times and it is just not correctly seated. At this point it is a PITA. What were you doing in the first place? Do you still have the shim for the shaft that sits against the case? Quote Link to comment Share on other sites More sharing options...
FBRT95 Posted April 24, 2022 Author Report Share Posted April 24, 2022 Thanks for all your answers. I checked it also with the Cover on of course Also everything is assembled correctly according to the manual I also found the problem: the gear in which the kickstarter gear engages was damaged on the inner side. So each time it should get back to the neutral position it hook in there and got stuck. Now i simply smoothed the edges of the gear and now it works fine Thanks again for all the input and have a nice sunday,! Quote Link to comment Share on other sites More sharing options...
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