250 SL kickstart stripped

[BlkVlvtRydr]

Looks like the kickstart on the 250 has stripped over. Anyone have instructions on what is required to fix this? From the looks of it, I'll have to split the cases. Anything to consider before I go that far? Any special tools required? Anything else I should replace while it is apart without spending a fortune? Does anyone make stronger kicker parts than the OEM ones I'll be replacing? Sorry for all the questions, I just want to know what I am getting into before I take it apart.

[Dale]

I "believe" that this is a common problem and that there is indeed an improved kick shaft, here at Strictly Hodaka, to replace the OEM parts . However, I searched for it and could not find it, nor could I find any posts regarding it. I must need more coffee... I would recommend that you contact Paul and see what he has for you.
Dale

[dirty_rat]

In most cases, yes, you will have to split the cases. What exactly are you referring to when you say the kick starter has stripped? Is it making a grinding noise inside the engine and slipping on the gears (which is actually the rollers slipping) or is the kick starter lever stripped on the shaft (outside portion)? In either case, Strictly Hodaka sells upgraded parts, but you have to split the cases to replace either. If unsure on which part needs to be replaced, I believe they make a kit to replace all the parts with upgraded parts.
To disassemble the engine you will need the usual hand tools and a couple of special tools, such as a flywheel puller to remove the flywheel. Overall, the engines are rather easy to work on. While apart, I would probable replace the seals and bearings (if the present ones are over 30 years old.)

[dirty_rat]

The kit is : Kick Crank Assembly Set- Part# 714700AKIT Just go to the Strictly Hodaka site, under category go to engine parts > kickers and parts and it is listed there.

[olddogs]

You could consider the dreaded "W" word. Weld it on. I have had over a dozen Hodaka 250s and half had the kicker welded on. I welded one a 250 ED when it stripped the day before an enduro. If the spring is still attached and it will return, you can stick weld them on through the open end of the kick start lever. I intended to fix it the right way after the season was over, but never did. It is still working 15 years later. You can still access the clutch even after they are welded on. To fix it correctly after they have been welded on, you can remove the engine and cut the shaft off with a saws all near the case. You can then split the case and do it right. Cutting them off is no big loss as you are changing the shaft anyway. Both the shaft and the kicker are usually stripped.

[BlkVlvtRydr]

Thanks for the responses. The exterior connection is just fine. The problem lies inside the case. I feel it vibrate over some bumps as I move it downward with my hand. It is almost as if (within the 250 SL parts diagram C attached below) part #29 is rolling over the shaft #27 close to the gear #28 keeping #30 from making a solid engagement. Looks like I'll be splitting her apart.

[dirty_rat]

What you are describing is a worn out roller holder (and possible a worn kicker shaft). The roller holder (part #30), holds the rollers in place; and when you kick start the bike, the rollers are forced up ramps (or cams) on the kick shaft, pushing them outward, where they are forced against the inside of the gear (part #28), turning it. As the roller holder wears out, the rollers aren't held in place correctly and you get the slipping as you described. I know Paul makes an improved roller holder for some models. Also, if the problem has persisted for some time, the cams or ramps on the kicker shaft might have also worn down, making a new shaft necessary.

[dirtsquirt74]

An excellent explanation.

[racerclam]

The kick roller retainer in the 250 is from the factory the good design and doubtful that it has failed , the ramps on the shaft more lickley wore out , I guess you will know when you tear it down. I do recommend the improved shaft and kicker from Paul though since it gets the splines al the way to the out side so you dont have the thing wobbling and always ready to fall off.

Rich