F`ed Xr250 whats Wrong And how can i fix it

**crazyxr250rider** · 26th June 2005, 17:25

I was ridi up gravel road and was leting the clutch out and the kick start flew down
i was in 3rd gear now in 1,3,5 gear when i let out the clutch out the kick start flies down and because of the auto decop it stops running

**merv** · 26th June 2005, 18:27

Never seen that happen before so I'm no expert on the problem. However, does it feel like the return spring is still OK, i.e. when you kick start does the lever pop back up OK?

If it doesn't right itself you are going to need to pull the right side case off the motor and have a good look at the kick start mechanism and try and figure what has gone wrong with it.

**crazyxr250rider** · 26th June 2005, 20:01

Originally Posted by merv

Never seen that happen before so I'm no expert on the problem. However, does it feel like the return spring is still OK, i.e. when you kick start does the lever pop back up OK?

If it doesn't right itself you are going to need to pull the right side case off the motor and have a good look at the kick start mechanism and try and figure what has gone wrong with it.

kick start returns fine not spring every thing works fine in 2,4,6 gear

**Paul in NZ** · 26th June 2005, 20:32

I've got NO idea how a Honda gearbox works (and not keen on finding out) but as a guess.....

Depressing the kickstart will turn summat in the box to turn the gearbox input and thus the engine. Doubtless there is a dog clutch, or something to do this attached to something in there that only goes 1 way. Soundslike something broke and now it turns with the gears on that shaft?

Get yourself a parts book or an exploded diagram and should not be too hard to nut out? Probably a 50c part and a $1000 labour bill deally!

Cheers

Paul N

or ask on a XR forum - must be one!

**crazyxr250rider** · 26th June 2005, 20:43

Originally Posted by Paul in NZ

I've got NO idea how a Honda gearbox works (and not keen on finding out) but as a guess.....

Depressing the kickstart will turn summat in the box to turn the gearbox input and thus the engine. Doubtless there is a dog clutch, or something to do this attached to something in there that only goes 1 way. Soundslike something broke and now it turns with the gears on that shaft?

Get yourself a parts book or an exploded diagram and should not be too hard to nut out? Probably a 50c part and a $1000 labour bill deally!

Cheers

Paul N

or ask on a XR forum - must be one!

Yeah same old story cheap part big bill

**Brian d marge** · 26th June 2005, 20:48

Originally Posted by crazyxr250rider

I was ridi up gravel road and was leting the clutch out and the kick start flew down
i was in 3rd gear now in 1,3,5 gear when i let out the clutch out the kick start flies down and because of the auto decop it stops running

Off the top of me head ... Can you kick the bike over ...If so the Ratchet pawl arrangement is ok ,, Sounds like the Retun spring is either A broken or B come out of its Slot ( difficult unless installed wrong )

In the mean time you can disconnect the cable ( waste of time those things , though the do reduce the loading on the kickstart arrange a little bit )

and use the time houred method of a bungy cord to hold the Kick start lever up

They If I remember often go like that and the repair isnt so difficuly ( it was 5 years ago since I did that prob on an XR ,,,so

Take the clutch cover off and have a look ( be careful there is a washer/shim that falls into the crankase easily ,,,,

Stephen

**crazyxr250rider** · 26th June 2005, 20:58

Originally Posted by Brian d'marge

Off the top of me head ... Can you kick the bike over ...If so the Ratchet pawl arrangement is ok ,, Sounds like the Retun spring is either A broken or B come out of its Slot ( difficult unless installed wrong )

In the mean time you can disconnect the cable ( waste of time those things , though the do reduce the loading on the kickstart arrange a little bit )

and use the time houred method of a bungy cord to hold the Kick start lever up

They If I remember often go like that and the repair isnt so difficuly ( it was 5 years ago since I did that prob on an XR ,,,so

Take the clutch cover off and have a look ( be careful there is a washer/shim that falls into the crankase easily ,,,,

Stephen

dont think its the return spring i let the clutch out the kick screeches then flies down only does it in 1,2,3 gear operates normal in 2,4,6

**Brian d marge** · 27th June 2005, 03:34

Originally Posted by crazyxr250rider

dont think its the return spring i let the clutch out the kick screeches then flies down only does it in 1,2,3 gear operates normal in 2,4,6

The Screetch sounds like a bearing ( metal on metal sort of like fingernails on a blackboard), and it only does it in those gears sounds like either the kick start gear plain bearing has gone ( the only Manual I could find is the XLS 250 which should be similar to the XR ,,( stand corrected ) and yup if the kick start gear which operates on the lay shaft has/ binding due say a shagged bearing ...this would cause a problem only when some gears are engaged ( and would cause the kickstart lever to go flying down .... and or one of the main/layshaft bearings ,,, the trouble is I cant remember the exact layout ,,I have tried downloading Manuals ,,but its just causing my PC to freeze( one of them unfroze for a seck thanks Adobe !! ) Either way that clutch cover is coming off not to difficult ,,,but when you put it back on the kickstsrt shaft may need to be rotated slightly to engage ..

Sorry I cant be much more help , As I said it was nearly well 1994/5 ish the last time I did a XR kickstart!!

If you can find an online manual ,, Then I could be of some more help

Kind regards Stephen

**crazyxr250rider** · 27th June 2005, 21:06

could you please post the site you were gtting the manual off
that would be a big help
PS is your cr silver had one awhile back

**crazyxr250rider** · 27th June 2005, 21:12

And i was told a week before xr250`s indestuctible (First xr and first 4 stroke)

**Brian d marge** · 28th June 2005, 01:30

I play about with bikes for a living, I had a vague rememberance of what was in side So I just went looking for the same type of Engine ...

IF you take things slowly its pretty straight forward ,, The thing is you want to Just take the clutch cover off ,,,,, and have a look for obvious damage ,,,around kickstart area ...then make a decision ...( If you go further than that , the clutch centre nut and pressure plate bolts are areas to stuff things up ,,,,,)

the link I used is this

I used the XLS 94 to 2000

But there you go ....

**NordieBoy** · 28th June 2005, 08:57

Originally Posted by crazyxr250rider

And i was told a week before xr250`s indestuctible (First xr and first 4 stroke)

We just stripped mine down the other weekend to get overbored and the cams look like new and the bore is perfect.
Looks like the rings havn't sealed properly though as there is a lot of crap on top of the piston so it's going to get run in hard this time.

Oh and it's 26 years old and gets raced in Classic MX

**crazyxr250rider** · 1st July 2005, 17:53

Originally Posted by NordieBoy

We just stripped mine down the other weekend to get overbored and the cams look like new and the bore is perfect.
Looks like the rings havn't sealed properly though as there is a lot of crap on top of the piston so it's going to get run in hard this time.

Oh and it's 26 years old and gets raced in Classic MX

well its fine from the botom of the cylinder up BUT every thing else is fucked
turns out ive twisted the internals of the gear box and bent the front sprocket shaft

any one got a spare motor just lying around
no? ahwell. do xr400s break as easily?

**XTC** · 2nd July 2005, 14:49

Originally Posted by crazyxr250rider

well its fine from the botom of the cylinder up BUT every thing else is fucked
turns out ive twisted the internals of the gear box and bent the front sprocket shaft

any one got a spare motor just lying around
no? ahwell. do xr400s break as easily?

How'd you do that??

**DingDong** · 2nd July 2005, 15:18

Originally Posted by crazyxr250rider

well its fine from the botom of the cylinder up BUT every thing else is fucked
turns out ive twisted the internals of the gear box and bent the front sprocket shaft

any one got a spare motor just lying around
no? ahwell. do xr400s break as easily?

??? thats the first I've eva.... someone might be bull shitting you to make some extra cash... you wouldnt be able to change gear with that shaft bent... actually you would need a sledge hammer to bend that shaft... is the casing cracked or leaking from the front sprocket?

somethings fishy... oQo<