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Makotosun

74 DT250 Kick Shaft Install

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74 DT250 Kick Shaft Install was created by dt3 steve

Engine Reassembly... I am having trouble installing the kick starter shaft on my 74 DT250. The manual does not really say how to install it. I know I must have some preload on the spring. I thought I had it in correctly, but it is ratcheting when I rotate the engine and I don't think that is correct. This is a lot different than other bikes I have worked on. Any words of advice? Does anyone have any instructions? I searched the forum and did not find anything. Thanks for any help.
21 Feb 2016 12:59 #1

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Replied by Makotosun on topic 74 DT250 Kick Shaft Install

I will be following this, but unfortunately don't have an answer for you. I believe the 74-76 models used the same setup, 250/360/400, and I have an issue with one of mine not engaging correctly.

Hopefully the answer will be posted.

Probably be helpful if you could post up a pic of what you are looking at.
IF it isn't one thing, it's another.
21 Feb 2016 13:05 #2

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Replied by dt3 steve on topic 74 DT250 Kick Shaft Install

I don't think I can get a good photo of the issue. If I were to guess, I'd stick the shaft in with the stob in the up position and push it in just enough for the slot in the end of the shaft to catch the spring. Then rotate counter clockwise until the stob will slip behind the retainer and push the shaft in and mesh the gears. However, this is ~180 degrees and I am afraid that I will break the spring. It goes well to about 145 degrees and then it seems like the spring is really wound tight. Then I am afraid that if you kick it (another 120 degrees) you will break the spring. I have never seen a kicker with this type of spring arrangement. On most bikes, this is a simple task.
21 Feb 2016 16:22 #3

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Replied by Makotosun on topic 74 DT250 Kick Shaft Install

Have you downloaded the factory service manual? We have it in the tech section and it may reveal the proper technique.
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21 Feb 2016 16:38 #4

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Replied by dt3 steve on topic 74 DT250 Kick Shaft Install

Yes. The factory service manual is useless. I am looking for a Clymers manual now.
21 Feb 2016 16:54 #5

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Replied by Makotosun on topic Re:74 DT250 Kick Shaft Install

I tend to use both as the Clymer manuals sometimes cover certain procedures better. Let me see if I can find the applicable pages of clymer. The manual number is M415


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Last edit: 21 Feb 2016 17:05 by Makotosun.
21 Feb 2016 17:02 #6

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Replied by Makotosun on topic Re:74 DT250 Kick Shaft Install

Here are the applicable pages:


dt250-400 kickstarter clymer.pdf
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21 Feb 2016 17:15 #7

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Replied by dt3 steve on topic Re:74 DT250 Kick Shaft Install

Thanks. The one I have is figure 3. According to this instruction, I don't add any preload to the kick spring. This does not make any sense to me. The kick starter will hang 1/2 way down it's travel because there is no spring tension. Weird. On most kick starters, you engage the shaft and then wrap the spring around (adding tension) and hook it on a pin/stop. On this one, the spring is inside the transmission and you insert the shaft slot to engage the spring. I have worked on many bikes over the years and am very comfortable with this sort of thing, but this is the strangest one I've seen. My Kawi H1 triple has an internal spring, but it is rather simple to engage. I guess I may need to wait for a response from someone who has installed a 74-76 DT 250/360 kicker. Again, thanks for your help and for the pages from the Clymer manual.
21 Feb 2016 17:45 #8

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Replied by Makotosun on topic Re:74 DT250 Kick Shaft Install

No problem. I have a dt400 with a kicker issue so I am most interested in the answer!


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21 Feb 2016 17:46 #9

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Replied by dt3 steve on topic Re:74 DT250 Kick Shaft Install

What is your problem? Maybe I can help.
21 Feb 2016 17:50 #10

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