My 2001 kx250 keeps breaking kick shafts after 15 or 20 kicks. i've replaced the spring, bushing, circlips, washers and now two kick shafts.

Never worked on this car to be honest but if the drive shafts are coming away from the gearbox end then i would look at the end of the shafts where they enter the diff as it could be that you havent fitted the circlips that hold the shaft in ?

IF YOUR KICKSTART HAS SEIZED AND IT WON'T TILT BACK IN THE PROBLEMS ON THE SHAFT (REMOVE THE DOMED ALAN CAP BOLT THEN REMOVE THE ACTUAL KICKSTART AND CLEAN UP THE SHAFT AND INSIDE DIA OF THE KICKSTART AND LUBE IT BEFORE REFITTING, MIND YOU DON'T LOSE THE SPRING AND BALL). IF ITS SEIZES WHEN YOU KICK THE KICKSTART THEN ITS THE KICKSTART GEAR OR BUSH IN THE SIDE COVER THATS THE PROBLEM. ITS EASY ENOUGH TO CHANGE IF YOU HAVE THE TOOLS FOR THE JOB. IF ITS A DIRT BIKE TRY TO PRESSURE WASH IT THEN SPRAY WITH WD-40 IT MIGHT HELP. GOOD LUCK IF YOU NEED HELP WITH STRIPPING IT DOWN JUST LET ME KNOW (ALSO LET ME KNOW IF ITS A LEFT OR RIGHT SIDE KICKSTART)

complete cylinder compression test. should be approx 120 psi
if low you will have to replace piston rings.

was bike running good before?

Great bike!

To get to the kick starter shaft and idler gear you will first have to remove the kick start and brake levers. Then remove the water pump cover and circlip, the impellor, and steel drive pin. Then remove all side cover bolts and pull the cover off the engine. Don,t let the water pump shaft come out of the engine when you pull of the cover . Suggest the best thing to do is set the engine in TDC with the timing marks on the cam side together. When the shaft come out you have to time it again, so hold it in place in the engine.

Hold WP shaft down with your thumb while pulling on the cover.

Once the cover is off the Kick Start idler gear assembly lifts out easy but as you put it together there is a center punch mark on the gear that goes in first that MUST be in aline with the spring hole drilled into the shaft, if not in aline the starter will engage at the wrong point.

Reinstall new shaft and idler gear in reverse order.

Just remove the right side cover to expose the kick start mechanism. Remove the bolt on the end of the shaft, tow washers and guide then the spring. It has been awhile since I worked on the KX 250, but as I recall, the clutch does not need to be removed in the process of replacing the spring. I could be wrong on that. Below is the kick mechanism on your bike. Please rate my answer. Thanks.

You remove the three hex drive bolts on the bottom. This will allow the bottom plate to drop off. Then clean out the glue in the little groove in the middle of what looks like a thick washer. There is a tiny circlip on the shaft which you remove very carefully. The thick washer, a spring washer and flat washer are then removed along with two metal concave parts. Note carefully the order in which the parts are around the shaft. You have to carefully pry off the plastic part right below the bearings. That part is pressed onto the shaft which is ribbed to hold it in place. Once you get the bearings back in place you press the plastic bottom back on. I had to use a vice grip to hold the shaft and needle nose pliers placed against the plastic like you holding the shaft then tapped the pliers to push the plastic onto the shaft holding the shaft up with the vice grips. Put the rest of the parts back together and put the circlip back in place. Be careful when placing the circlip. Mine wasn't all the way on and popped off. Now I can't find it. Once you get the circlip back on use some shoe goo or similar material to lock the circlip into the groove on the thick washer. Let it dry and reinstall the the bottom with the hex drive bolts.

You will need to remove the right sidecase cover to get to the starter assembly. Once inside, you should be able to see any broken parts. If no gear, shaft, cam or ratchet problems are present, a circlip could be broken or the springs may be weak and need replacing. Chances are the clutch will need to be removed to make repairs to the starter. Please rate my answer.

http://www.mxboards.com/forums/viewtopic.php?f=1&t=462

Remove clutch cover and check to see if clutch is actually disengaging. Either it is not hooked up properly or it is broken.

now then, i have a kickstart, i bought it for my kx 125 1999 but it doesnt fit it you send me the dimentions of the bolt it fits on to and the one i have will fit ill sell you it