This one has me baffled. The kickstarter gear works fine until you put the side case back on, then it doesn't engage. The case shouldn't have any effect as far as I can tell. Take it off and everything is still in place just fine and it works again. Any ideas? It's a '96 KX250. I'm thinking a weak ratchet gear spring. The teeth may have some wear but look pretty good. Do these fail with just a little wear? But why work when the case is off but not when you put the case on?
