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I have a 1993 GAS GAS 250. I finished my last event and was goofing off in a section when my bike sunddenly quit. When I went to kick start it again the kickstarter would not move at all. I am only a NOV. so I never do any thing strenuous to damage my engine. My bike was ridden by a national rider for 2 years and then a expert untill I bought it 3 months ago. I took the cover off the cutch side and can move the engine using the bolt on the crank. So I know the engine is not seized. I then suspected ether the trans or the kick starter gears, is that right??? I cannot see the kickstarter gears because they are behind the clutch. After removing the clutch plates I was greeted by a bolt on the free wheeling part of the culch in the middle of the cluch basket. How do I remove that bolt so I can rule out the kickstarter before pulling the engine and spliting the case.

Info: I use... Silkoline premix at 95:1, ATF DEXRON and change it every two rides

thanks, Jacob,

I'm assuming that you have very good mechanical skills and the proper tools. If you're not sure what to do, I'd let your local Gas-Gas dealer have a look at your bike. I think your diagnosis that it's the kickstart or transmission gears is probably correct. I'd look at the kickstart gears/assembly to begin with as that's fairly easy to get to and understand how they operate. As I remember, the clutch hub nut is a 24mm and comes off in the counterclockwise direction. An air wrench is the easiest way to remove that nut. To keep the clutch hub from rotating while taking off the nut, stuff a shop rag in the gears between the primary gear (on the end of the crank) and the clutch hub gear (the large outer gear on the clutch basket). This way you won't damage the gears. The kickstart assembly is behind the clutch on the upper left side. There is a possibility that the rachet pawl (they look a little like shark's teeth) is broken or seized in some way. Be sure to keep track of the order in which the clips, spacers, spring etc. come off as they need to be assembled in exact order. If you look at the parts photos on the Gas-Gas webpage, it will give you a general idea of what a kickstart assembly is composed of, although those parts are for the 2001 models only and may differ from yours somewhat. If the problem is in the transmission gears, you will need to have the necessary experience, knowledge and specialized tools to do the job. I'd think about having your dealer do the work as a mistake in the many critical steps of disassembly/diagnosis/repair/replacement/assembly can cause irreparable damage to your engine. Transmission work is probably the most difficult and demanding job a mechanic can undertake and there are a lot of little clues you need to look for.

A good way to avoid damage to kickstart assemblies is to take up the slack by pushing down on the kickstart lever before raising up your body and using body weight rather than leg strength to exert pressure on the lever to kick the engine over. This will engage the pawl teeth without damage. A lot of riders just jab their boots at the kickstart lever and over time this rounds off the teeth or damages other parts. This starting process is good for any brand of motorcycle and will make the kickstart mechanism last the life of the bike.

Let me know what you find.


Professional tuner and 'Trials Competition' writer Jon Stoodley has very kindly stepped up to the plate to answer your questions. If you're having problems, or need some advice just send an email to Jon. If it's something that could be useful to others, we'll post it on the site.
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