ktm300mxczz,
I don't know who you are or where you came from, but how about giving us DRNers a little clue as to your background and employment? Your profile is blank. You sure seem to be dispensing alot of authorative statements lately in your short tenure here at DRN. Please, clue us in. We're always looking for talented contributors here at DRN.
As to the kickstarter parts - KTM did have a recall in '98 to replace the stationary half moon-shaped part that the engagement pawl rides under. '99 and later should not be a problem with THIS part. The pawl itself is another story. There are three parts in there - the pawl, a spring, and a pin. The pawl and the spring are both subject to repeat problems on these bikes. Not a high incidence of failure mind you, but when I broke my pawl the dealer (Mikes Cycles in Baton Rouge LA) told me that they always stock these, the spring, and the pin. The pawl is subject to breaking on the thin edge around the back side of the pin. More common though is the spring itself wears, causing it to thin on one side and and eventually fail. Westex, this is most likely the cause of your problem. If it disengages OK and does not give a rattling sound when the engine is running then the pawl is probably OK. BUT, your slap-kicking it to give it enough centripital force to engage is HAMMERING the weak little pawl.
If it were me and I went to the trouble to pull the side case off, I'd go ahead and replace the pin and pawl as well as the spring. I can't remember if you can get to the spring without pulling the basket. To get to the pawl you definately must pull the basket. The most difficult part of this whole thing is getting the kickstarter off. It will most likely have tried to weld itself to the shaft, so pull the retaining bolt, lay the bike on its left side, and start soaking it now with some release fluid now.
Let us know if you need help getting the inner basket nut off. It can be done easily without any special tools. Just don't use that vice-grip like thing. Also keep an eye on the roller bearing and washers when you pull the outter basket off the shaft - you don't want these to hit the floor.
If you do replace the pawl, you'll need to press out the old pin and in the new one. I used a bench vice, a 1/4-20 or 5/16-20 nut, and a chain pin to do this. Again no special tools required.
Oh and, do Strick's little chamfering trick. I didn't hear of this until after I got mine back together.
Good luck,