98 220R kick assembly

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johnyblaze
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98 220R kick assembly

Post 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
1998 KDX220 with goodies
2002 KTM LC4E
2001 Suzuki Bandit 1200S
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Slick_Nick
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Post by Slick_Nick »

Stock kicker sucks bigtime. Could be there've ratchet mechanism is slipping a bit too.
'00 KDX 220R
gregp
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Post 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.
2004 Dual Sported KDX200
1999 Ninja 250 (Daughter's)
1996 DR 650 (stock, mostly street use)
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