kickstarter question

[mxdad316]

I'm building a 2001 ec250, just cranked it yesterday for the first time since I have owned it. I put a new bottom end and top end so it's like brand new. It seems like the kickstart lever moves a long way before it engages with it's gear to spin the engine over. I think about 4 inces or so before i feel it catch. It works fine but it has a very short stroke before it hits the peg making it tough for a short guy to get a good kick on it. Is there a possibility I put the gear in the case wrong causing this, or do all older gasgas bikes have a short kickstart stroke? I read about the yz250 kickstart lever swap a lot of people have done and thought it may be helpfull. Thanks

 

[jostby]

You need to remove the clutch cover and wind the ratchet gears up a couple teeth. That's your problem. The YZ kickstart works good but won't solve this problem.

 

[mxdad316]

Thanks, I'll do that today. I must have let the gear slip on the shaft when I installed it. In the past I have seen jap bikes with dots to align the gear ratchet assembly but I did'nt look too closely on the gasgas. I will say this, the quality of the gasgas engine castings and internals look to be better than a lot of bikes a I have worked on. I can't wait to ride it!

 

[GMP]

Its not about winding the gear but making sure the spring is installed correctly and the pawl is seated so it hits its stop. When all is good the spring has proper tension and gear proper engagement.

 

[mxdad316]

I removed it all, and it was just like it should be. I ended up modifying (shortening) the steel strap that holds the pawl. It is not a big improvement but I gained another inch or so that the lever travels & it feels a little more like I think it should. I compared the levers on the gasgas and my rm250 and the gasgas looks like a 125 kickstarter! It will do until I find a yz250 lever. Thanks for the help, now I'm just a fork rebuild away from the test ride!

 

[Moto-x]

i have a 04 300ec and it has a yz kicker on it and it works way better then that short kick starter