Kickstart ratchet wear

[Johnniespeed]

It has been about three years and my kick start has worked perfect ever since sharpening the ratchet teeth.
 I strongly suggest this to anyone who has kicker engagement problems.
 John

[Purpletj]

Bumping a good post.

[kwakman]

this mod has been mentioned on here johnnie. ive just done the same thing to my new ratchet, as the guy who'd done it said it worked well. also, you might want to stretch the spring slightly as this helps push them together, as when you look closely and operate it you can see the teeth push against each other and the gears move away from each other slightly, and this is what starts the wear over a period of time.

[demographic]

Apparently nobody has noticed the kickstart ratchet teeth are not a machined surface. Ok so I will be the dumb guy to try something unproven.  I took the ratchet and spur gear and reshaped the ratchet teeth so that they are a 90degree surface from the shaft. Now both of the surfaces have a flat contact surface and should not slip again.  I have started the bike about a dozen times and ridden it twice, it works perfect.  This is one of those modifications that will not prove or disprove itself until much riding and time.
  It still would be nice to hear from anyone that has tried this or understands what I am talking about.

Great stuff, what did you use to machine the surfaces to 90 degrees?

I have a spare kickstart ratchet gear in the shed, ready to go onto one of my KXs that has problems, I'll post up a picture of the gear if you want and I'm pretty sure I know the area you mean.

[Johnniespeed]

 I did that back in 2006 using a dremel with a grinding tip. I spent a long time checking and rechecking that all teeth make good contact. My kickstart has worked flawlessly ever since, the only cost was the gasket. I have one of those magnifying lamps that helped see closely the teeth and thier contact pattern.
 My bikes getting old, it's a 2004, but I still think it's the best bang for the buck. I still run into riders who think thier new 450 four stroke is the fastest bike in the world, then the old KX has to spank em, next comes thier excuses. You all know what I am talking about.
 John

[Hman636]

Hey, on that 92 k5 that im re doing for a friend, i got the gears back together and they are working great thanks for the help but wheni put the case back on the kick start wont ratchet back up. any help?

[Goat]

Hey, on that 92 k5 that i'm re doing for a friend, i got the gears back together and they are working great thanks for the help but when i put the case back on the kick start wont ratchet back up. any help?

Make sure you have the plastic spacer groove lined up with the spring that goes into the shaft of the kickstart and that you have the shim on the shaft behind the gear on the shaft. It's binding up and wont retract. I just had that issue with my 93 and the plastic bushing wasn't lined up properly.

Johnnie I want to thank you for this writeup. Bought a basket case a month ago. I just got my engine together for the first time and noticed the kickstart slips. I will pull it back apart and check this out tomorrow. I glanced at it today and thought it looked fine so I checked everything else out and put it all back together and it still slips.