1985 ATC 250r kickstart slippage Service update

[croat1]

not sure where one would find this paperwork (except dealer service Dept.) but I stumbled across it and figured I would share.

[broken1]

Thats a cool find. I wonder how many 85 engines actually got marked with an X after the service?

[croat1]

found another Service Bulletin for the same problem.  Notice the pic about making a "X".  the warranty information is also interesting

[Jerry Hall]

The Honda dealers in the Phoenix area could not get the Pinon and Ratchet gears from the Honda parts network.  The dealers sent the bad gears to me to back cut.  I would estimate I cut over 500 of these gears sets.

[The norm]

I am battling this problem on my son Coopers engine. I have a mountain of parts that I will dig through to find the updated parts. I'm wondering though if I have to swap out everything? Could I just change the pinion gear and the collar? Are all the parts different from the problematic 85 parts? I tried to use the updated collar, but the damn thing still slips! So today I am going to try to find a "86" gear. I don't see any identifying marks on the kicker parts so it's going to be a mix and match situation until I get the correct combo.
Loren

[croat1]

Loren, check out this thread:

https://www.forums.trx250r.org/index.php/topic,4897.msg52895.html#msg52895

Joe

[Hawaiiysr]

That makes me want to change my spring just because.
What happened to Ryan? I know he's a busy guy. And his water pump shaft he disappeared

[The norm]

I ordered the spring. Hopefully that is the cure.

[broken1]

That kicker gear I sent you a couple months ago was 86.

[dp250r]

Im thinking about ordering  #5 from a 450r

[Jerry Hall]

Im thinking about ordering  #5 from a 450r

I doubt if a stronger spring will stop it from slipping.  The spring just gets the ratchet gear close enough to the pinion after the kick starter shaft rotates, they start their engagement process.  Once the gears start to engage, the back cut of the two gears suck the gears together so that they engage to there full depth.  If the back cut edges of the two gears are rounded off, the gears push apart when torque is applied.

The pinion and ratchet gears back cut edges have to be in good shape or they will slip, especially on engines with a big bore kit. 

[dp250r]

I figured this would be a good thread to post this in.The 2 thin washers on either side of the collar are discontinued for 85 250r I ordered #10 cr 250r from partzilla schematic and its an exact match.

[The norm]

To fix the slippage issue in my son's engine I machined a new shaft collar and stretched the original spring. I ordered some new spring material from Mcmaster-Carr just in case the stretch job didn't work. Well as of now the kickstarter gears do not slip. I'm not 100% sure at the moment, but I think the 85 collar is .010" shorter than the 86 collar. I would have to consult my notes to get a definitive measurement.
Loren

[croat1]

Here’s the box

[croat1]

The replacement parts…