Need help with kickstart

[canuckhybrid125]

I have a KDX220 motor and the kickstart only starts engaging half way down on stroke.Sometimes it does not engage at all.Does anybody know what could be the problem? I dont have a service manual yet.
Thanks

 

[julien_d]

There are two gears that engage to ratchet the kickstarter. Either those gears are worn, or the spring that keeps tension on them is worn. Sometimes you can remove the assembly and stretch the spring a bit and it will work again. If you pull the inner clutch cover and the clutch basket you can remove the entire kickstart assembly. It is not the big tension spring you see in the front, but a smaller spring in the back that keeps tension on the two ratchet gears.

 

[canuckhybrid125]

Thanks for your help! julien_d

 

[KIWI KDX]

hey mate, the two gears are more than likley the problem, they wear its pretty common, take the kick start apart and take them to an enginer and get them to undercut the gears.

or if you know what ur doing, do it yourelf with an angle grinder.
i did mine with a angle gringer about 2 years ago and its been mint ever since.
hope this helps.

 

[canuckhybrid125]

Great help guys,thank you.