250-500cc about that decompression head

A year ago I decided I would need to freshen the top end on my '94 wxc360. It had always run well, but it was a bit down on compression. Well, I just buttoned it back up, and I almost got it started up when I broke the kickstarter in half. Another good kick, and I think it would have caught. Looks as if the pin bent and then the lever let go.

Aside from fixing a worn piston and an air leak, nothing should have changed. I went back with the same .020" base gasket, and went up to the next letter piston. I have the receipt from when the previous owner did a topend, and it does say they sold him two .5mm gaskets. I only see the one. I can't think of what I could have done weird, but I don't want to kill another kickstarter or the case. I have heard that it is mainly the later bikes that need the decomp head, but this thing takes some boot to kick. Anyone running a decomp head on one of the older cylinders?

Edit: there were two gaskets! Time to bust it down again!

I'm pretty quick doing topends on these things now! Have both gaskets in place. Ended up with a .3 and a .5 - should help kill off some compression. I guess this is the best time for a kickstarter to break. Would suck 15 miles back in the woods.

.8mm was stock back in 1994 fyi.

did you do the squish check?
piston in cylinder and bottom out
put on bike check difference

Not the first time, but then I saw the post on here about it before I tore it down again. Definitely needed the two gaskets to be in spec, but no collisions the first go. Lots of compression though

The bike runs! I am still waiting for a 250 kickstart to show up from overseas, but I was tired of it not running so I did a little push start action. My wife isn't going to be pleased with the skid marks in the driveway, but she should be happy the bike is functional...if I have a decent hill.

overseas? where are you located?

I'm in Texas. Hall's acted like they have one in stock, but they are $30+ higher on the part + $14 shipping. I'm not in a rush, and I needed some other stuff from motosport at the same time. But yeah, unless motosport and two other dealers (the local & Munn) were mistaken, there are none in US warehouse(s).

my dealer has one

I'm guessing they were a dealer before the ktm adventure began.

For next time: Who is your dealer?

I laughed when I saw this ad on ebay. Mine must be worth like $60 since the pin is still in one piece!

"Up for sale is a kickstart pedal removed from a Husky CR250, year unknown and there is some damage and a broken bolt but it can be repaired."

Here's a good looking kickstart lever on ebay for $60:

https://www.ebay.com/itm/00-Husqvar...ash=item3629fe6c18:g:mzMAAOSwrslaXkRy&vxp=mtr

Thanks for that! I bought it. I have bought several things from him/them in the past, and his stuff is usually clean and well described.

Glad that worked out well for you!

Received it yesterday and just came back from a shakedown run with the new front end, top end, intake boot, kicker, and carb. 13 miles in, and all is good with the world.

I have an '02 Husky CR250 that I made into HELLUVA CR300 ( thanks to the folks at Millennium Technologies for the big bore, port work , correct squish and hi -comp head). That last note about hi compression didn't work very well with that odd shaped kick-starter , so off the head went to Larry Weichman to do his magic installing a factory looking decompression valve--- WHAT A DIFFERENCE!...kicks over like a 125! Even if you don't have the hi-comp head, this mod makes it stupid easy to start. I posted this previously, I'll try to find it...His number is 815-623-8940

I can also vouch for larrys work. I have a 300 kit on my 07 w/hi comp head and 60 year old legs. The compression release is like magic and it looks like factory made.