So today I went to my local dealer to check out some used bikes. When I arrive there I notice little puffs of white smoke drifting by me. It's coming off the exhaust. I look down and my right shoe is covered in oil! I just did the oil last week and figured I must have not have tightened one of the bolts. I look a little more and THE KICKSTARTER HOLE PLUG IS GONE! Must have popped out somewhere during the ride. The right side of my bike is covered in oil and I have no idea how many miles I rode it like that. Not all the oil was gone, so I believe is was probably less than a mile but who knows. Bike didn't act funny at all.

One of the mechanics was able to find a cone-shaped piece of rubber and jam it into the hole so that I could make it home no problem after he topped off the oil. I also ordered a replacement plug.

I think the bike knows I'm looking to possibly trade it in for a bigger bike and wants to kill me. Now I don't trust the factory hole plug even though the shop has never seen this happen before. So I've got two choices as I see it.

1) Replace the plug and trade it immediately.

2) Add a kickstart and keep the bike.

Anyway, just wanted to give a heads-up to a problem that will probably never happen again to anyone.

On a positive note: The bike rode home fine and was no worse for wear after this incident.

This is the first time I ever heard of this happening. Have you previously manipulated the plug for any reason?

I would throw a kick start kit on the bike and ride.

Absolutely never. Is there any way that oil pressure blew it out? I do run the bike hard, but this is kind of nuts.

I should still have the plug from mine if you don't wanna get the kick starter kit. Best of luck!

Thanks Adam. I appreciate it, but I already ordered a replacement. Did you do the kickstart installation? What instructions did you follow (the ones here on XT225.com?) How did it go? Thanks again.

Make sure you check that the crankcase breather tube is not pinched.
That could cause excessive crankcase pressure,possibly enough to blow that plug out .

The kick start kit was easy to put on mine. The hardest part was cleaning the old gasket off the case and cover. I followed the translated instructions available from this forum.

Yeah, I put that kick starter in before I was on this forum, I used the instructions that were in the kit. I learned the hard way that the clutch bolts are best to torque by hand...not a 1/2 torque wrench LOL. Also, I had to weld some claws on a cheap vise grips to make a mock flywheel holding tool. Probably wasn't nessicary, but it worked for me.

If you go thru with the kit, just be sure to go back and check the screws around the side engine cover that is removed. Last year after a 20 mile, I noticed that my rear tire was covered in oil, I was instantlly upset! After looking over the bike, come to find out a bunch of the screws worked themselfs loose and oil was just leaking out there. Tightened everything up and it's good now. I'd suggest some blue thread-loc to prevent that from happening.

For $107, I think that the kick starter is a very worthwhile investment. I really wish that my 400EX had a kick starter sometimes, luckilly the battery in that is still good so there's no worrys...yet.

Thanks for the info fellas. Road Rash, which one is the crankcase breather tube?

It's the large black hose on the left side of the bike that goes from the crankcase to the airbox.

Well, I think Road Rash nailed it. I went out to check that hose and it was kinked (folded over on itself). When I was putting everything back together after the valve inspection, I must have really screwed up the routing of that breather tube. I believe I have it positioned correctly now. It comes up out of the airbox, then goes across between the petcock and the carb. No interference with the fuel line to the carb. Does that sound right? Thanks again Road Rash and everyone else. Reaffirming that this is a great site. Tough little engine, too!