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My kick starter would engage sometimes. Most of the time I was kicking air. I finally tore down my bike yesterday but I didn’t really see anything wrong with the kick starter mechanism. Teeth look good, springs look good, splines on the shaft looked good. Any ideas of what could be the issue? I’m going to clean it very good before putting it back together. How do I post pictures? I will put some on here

Spring 92081A might have lost some tension.
I once had an 87 with the same problem and that spring was the culprit.

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Any chance the teeth are worn down?

Just finished repairing same problem on 02 220. Had a shop offer to undercut the pawl and sprocket teeth and I replaced the pawl spring. Works great now. The gogs looked good to me but the shop mechanic showed me that the teeth corners had been rounded off. They looked good to me. Don't bother putting it back together without either undercutting those teeth or getting new ones and replacing that little pawl spring. I had mine apart 3 times because I didn't think there was enough wear on those teeth. I was wrong!

Pat Reilly
Rockford, IL

Somewhere on here is a picture from someone who had his filed / ground / cut and they looked SO much different than usual. TOTALLY squared off.

I decided to order that small gear and spring. Hope it fixes this issue

Chilly, Good luck. Measure the difference in lengths of the old and new springs. My new spring was twice the length of the old one. I figured that new spring would correct the problem. I was wrong. Take a good look at the driven gear cogs. It doesn't take much wear and they will slip by. I still can't figure why the stock OEM angle is on the gears. Square cut, as the shop did to mine, seems like the way the original should be.
Keep us posted on your success.

I ordered springs, gear, and all. Figured why I had it all apart I better do it right the first time. I put it all back together yesterday and so far it looks like everything is working good. Can’t wait to ride again

No old gear / new gear comprison pics??

No I didn’t take any pictures of the new one. I compared the new to the old and didn’t see a huge difference. My 99 kdx has now a brand new lower and top end. Surly I can ride now without any issues. I’m to deep in the hole to get my money back so I hope to pass it on one day.