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98 220R kick assembly
Posted: 11:12 pm Oct 21 2010
by johnyblaze
My 220's kick lever drops a long way down before it engages. Only about the last 25% of it's travel seems to yield any movement of the engine.
I've never taken a kick starter apart. Is this likely to be a worn idler gear or something else within the assembly?
TIA
Posted: 02:34 pm Oct 22 2010
by Slick_Nick
Stock kicker sucks bigtime. Could be there've ratchet mechanism is slipping a bit too.
Posted: 06:51 am Oct 23 2010
by gregp
The kick start lever on my '04 200 also drops quite a bit before engaging the ratchet (but not 75%!). I was able to rotate the knuckle forward one tooth on the splined shaft to get a longer kick on the lever. The very tip of the lever contacts the FMF pipe, but it doesn't hurt anything. The upside is that the bike starts much easier now.
I have not pulled my ratchet assembly apart yet, but I would guess that the teeth are very coarse, so engagement takes a while.