kick starter return spring

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
Post Reply
patreilly
Platinum Member
Platinum Member
Posts: 129
Joined: 07:25 pm Nov 28 2016
Country: USA
Location: Rockford, IL

kick starter return spring

Post by patreilly »

My 2001 200 had the kick starter slipping by. I replaced the ratchet spring and put the case back on no problem. However now the kick starter lever does not return. When I remove the case the lever returns again.
Looking at the spring, it seems to hang out a little beyond the nylon inner bushing. Is there a trick to getting the return spring all the way seated before replacing the case. Case went on fine. But, I am thinking maybe the spring is riding on the case and binding.
All advice will be appreciated. I expected more trouble getting everything lined up replacing that case. But, I took it slow and used the kick starter lever to match up the gears just as the manual suggested.
User avatar
SS109
KDXRider.net
KDXRider.net
Posts: 5770
Joined: 05:11 am Aug 23 2009
Country: USA
Location: Tucson, AZ, USA
Contact:

kick starter return spring

Post by SS109 »

Did you preload the spring? When you install the kick gear assembly the spring has to be wound up and the end installed in the hole.
Youtube Channel: WildAzzRacing
AZ State Parks & Trails OHV Ambassador - Trail Riders of Southern AZ
Current KDX: '98 KDX220
Old KDX: '90 KDX200 -White/Blue
'11 GasGas EC250R
Post Reply