Maintenance & Technical > KX500 Original
Kickstart ratchet wear
KDXGarage:
What did you use to get the ratchet gear and spur gear cut? My 1991 KDX250 has rounded off teeth on the gears, and it had to (currently disassembled pending a rebuild) get a few kicks to find a place where it would catch.
Thanks!
Johnniespeed:
To do it right I would have used an indexing head and surface grinder. However I no longer work in a machine shop, so I did the best I could. I clamped the gear to the work bench, used a magnifying lamp, and did it free hand using a small die grinder ( dremel) and a grinding tip. I made sure I was sitting down and braced my arms against the workbench. I used very slight pressure and checked the gear against the ratchet. I went around both sets several times, fitting them together for an "eyeball fit" Since nobody seems to have tried this before, I spent a real long time to get it as close as I could. The kickstart has worked flawless ever since. Time will tell if this is a long term fix.
If anyone has the equipment to do this in a precise manor and has the desire to machine out a few sets, I wouldn't mind having a spare, "just in case"
Johnniespeed:
Just an update on my kickstarter modification from two years ago. The kickstarter has worked flawlessly now for two years. It never slipped again after sharpening the ratchet teeth. I recomend this super cheap fix to anyone with a slipping kickstart ratchet.
John
nd4speed:
I understand what you are talking about and may try it.
But on another note my kickstart gear started slipping like this on both an 86 Tecate 3 and an 86 Kx250.
Did not have a problem until the waterpump seals went bad and the oil became contaminated with coolant/water and turned milky. Replaced seal and oil and no more slipping.
Johnniespeed:
This is the topic I wanted to draw attention too.
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