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kick starter return spring

Posted: 09:19 pm May 18 2017
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.

kick starter return spring

Posted: 02:32 pm May 19 2017
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.