Weird kickstarter problem

My KX250 has a kickstarter problem which is frustrating me.

When kicking the engine over, the lever makes a thick sounding click, then frees up and go almost all the way through it's stroke. Near the bottom it catches again (so I have about 2 inches of usable kick to start the bike).

The bolt holding the lever on the kickstarter shaft is tightened and the splines on the shaft and lever are not stripped. The top end has very good compression.

Now - if I don't put any weight into my kick (like if I pull the lever down with my hand), the kickstarter catches near the top of the stroke like it should and won't let go through the entire stroke. Only when I kick like I need to when starting does it *click* and fall most of the way through the stroke (to the last inch or so, where it catches again and will eventually start the bike).

Yesterday I pulled the right side engine case, then removed the spring, collar and entire kickstarter assembly. I didn't have a micrometer handy but nothing appeared overly worn, stripped, or broken (and there weren't any metal shavings in the transmission oil). The primary return spring isn't broken either.

The only thing I noticed was a teeny tiny tiny bit of side-to-side movement between the shaft gear and ratchet teeth (the parts that make the little clicking noise when you release your kick lever). There is no movement between these gears along the kickstarter shaft (and the spring pressing the ratchet appears to be fine - it's hard to lift the ratchet up due to the spring pressure). The movement between the teeth is barely noticeable.

Any ideas on what could be wrong?

Kind thanks,
pk

Doesn't matter if I pull it down an inch or halfway through the stroke -- the second I put my weight into it something clicks and the lever goes down to the footpeg.

YZThumper said:

I can almost guarantee you need the spring behind the kickstarter ratchet gear. This is a very common problem on all KX models and happend to me last year. Mine had the exact same symptoms, where the kick starter would catch sometimes but most of the time kick straight through with just a clicking noise.

Click to expand...

That was it. :) I replaced the rachet spring with a new one and my kickstarter works like new again. Thanks for your help!