My friend needs help he's got a 2000 kdx220r. At the last race kickstarter gained about 2" of free travel before it catches. We pulled cover and examined mechanism and found nothing apparent. No stripped gears or broken teeth. put cover back on and hand engaged lever several times and then all of a sudden boom same problem. We've hadd it apart 3 times and still see nothing wrong. Any ideas short of buying the whole assembly new?