Tech question 1981 GS 250

[Dave Withrow]

I am having a problem getting the kick start to engage under "load".  it seems to drive the kickstarter gear fine when i push slowly or pull the spark plug.  When I have the plug in and kick it through, the gear doesn't engage very well.  I looked at the gear and it doesn't seem to be worn very badly. I was wondering if the spring may have weakened over time/use.  Since the set up is basically the same for KTM motors up to that year, I was wondering if anyone has had the same problem and what the cause/remedy was.  Thanks for any help.
Big Dave

[Mike Lenz]

Is this the old engine or the new 81 model.  Call me 309-231-6477

[Bill Campbell]

Dave. A couple of years ago I had this problem. I was pretty sure I put the engine together correctly but the kick starter would not work. I forget precisely what happened. I put a new return spring in and it worked just as fine. I could see no difference in the springs but the old was probably past its use by date. By a new one as they are easy to replace.

Cheers Bill

[Dave Withrow]

Thanks for the advice.
Bill-the kick start lever kicks through and returns fine and will engage the gear with the spark plug removed or done slowly.  It won't engage when the plug is in and kicked through quickly.  It's as if the clutch is engaging.  The search continues.......

[adrian_goold]

Be sure to check the idler gear is OK, no teeth missing, same for other gear, and that the roller bearing is new and the washer that holds the idler gear is new as these wear as well. All these things allow the gear to move around too much.
An 82 250 idler gear, i have found, ktm replaced this bearing with a bronze bush which stopped all the problems. Prior to this i had damaged kick gears (teeth break off).
As per the manual(or tech service bulletin) for 81 250, i think you have to shim the gears to have the correct distance between dogs. Also check your clutch cover as these wear in the area that the gear rubs.
I had numerous issues a while ago , but have since sorted them.






Regards,
Adrian Goold #101
http://www.ozktm.com

'73 175 Rebuilt.
'74 400 Now Racing!
'78 250 running soon!
'81 250 Now Racing!
'81 495 Engine Work stage.
'84 125 Now racing!
'07 300

[G Ellis]

Well after a lot of head scratching, we have figured it out. Dave bought the bike over,after 4hrs I told Dave to leave it with me. I cut an old junk side cover apart to hold the kickstarter in place. When the kicker slipped all the gears would turn but clutch basket would not. The trouble was the double drive gear would spin on itself. I found the double gear is actually two peaces. They are pressed together. Put a new double gear on problem fixed.

[Mick Milakovic]

Gary, an old junk side cover?  Now I can't throw anything away!

Mick

[G Ellis]

I never throw anything away.. This side cover was so bad I thought it might come in handy some day.