250sx kick start shaft removal

[m brater]

Trying to get out the kick start shaft so I can get the counter shaft back in (older post). The book says to take off the centrifcal clutch and manual clutch but the idler gear below is already dropped down from counter shaft being out. The book shows kicker shaft being pulled out by hand. What holds it in? How do I get it out?

[Woodsrider]

You have to put the kicker back on the shaft temporarily, turn the assembly clockwise to disengage the return spring from the case (you'll feel it when the spring lets go),and then very carefully pull it out ...this is the tricky part because there is a thrust washer at the very end of the kicker shaft....it might stick to the case...or it might stick to the end of the shaft, and if it does, you don't want to bump anything on the way out while extracting the shaft, because you might knock the washer off and it could drop into the crankcase. The thing is, you won't know where it is , so you have to proceed as if it is stuck on the end of the shaft ,just in case.
If I missed something, someone will chime in to help. Have fun.

[m brater]

Thanks a bunch woodsrider! How hard is it to get back in?

[Silverado]

It is very tricky to get back in. You have to seat it in just right and wind it till it catches. If you are lucky you can get it in one or 2 tries, but I found it very hard to correctly place back into the little slot and have the spring catch

[Dirtcrasher]

To put it back in lay it on the left side, put grease on that washer. If it's missing, it's already in the bottom end but a magnet can snag it.

Put the kicker shaft BARELY in thru the washer and about 1/8th inch. Rotate clockwise until the dog leg on the ratchet gear is behind that catch on the case.

NOW pop it all the way in, your done.

I do have to angle them a bit sometimes to get over that catch, you'll see what I mean...........