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on my 91 200 i can kick the bike 40 times and only have it catch about 10 times. i tryed the atf fluid didnt work. i wanted to kno if theres any other tricks i might try b4 i tear the side of the case apart. its really pissing me off to take 10 mins to start the bike. is there any way to fix the ratchet?

Pretty easy fix. You need to replace the ratchet gear, spur gear, and tension spring.

You kno what year assembiles i can use and if there from a kx? Looked on ron ayers close to 100 nucks for the two gears and 5 bucks for the spring. Do u really need both gears or just the one?

I suppose you could take them out and have a look and see which is worn, but since the teeth interact between the two gears, they probably both need it. You could try replacing or stretching the spring first for a quick fix. Might help.

I wouldn't bother trying to stretch the spring because you have to take off the side cover and spend the time to get to it. Probably not going to be the spring, but the teeth that are worn out. I used a dremel tool and cutoff wheel to sharpen the teeth and that held up temporarily.

I then purchased one off ebay for $35 shipped last year and it has been working great. I think any kdx 200 or 220 gear set will fit but check first of course. Just don't get a gear set that is as worn down as your own if you buy used :)

When u ground down ur ratchet how long did it hold up? I might run the bike 2 maybe 3 times a month.

dnovack wrote:When u ground down ur ratchet how long did it hold up? I might run the bike 2 maybe 3 times a month.

I would say it improved it so that I could at least start the bike, but I had to be really careful about kicking it still. It was really sensitive and prone to slip. I'd just go with the newest kicker gear you can find at a decent price and swap it. Buying the two gears new is an option too I guess. I'm just cheap

Id like to buy new gears but for 100 bucks i think i can find a few used ones.

I thought I had a set out in the garage. Just went out and found them. I'm pretty sure these are in serviceable condition, as I can't see much wear on the teeth. They came with my 89 when I bought it. The PO thought that was the problem with the kickstart not engaging, but it turned out to be a crack in the engine cases where the kickstart gears seat, so I never used them. Let me know if you're interested and I can get a pic or two up for you.

Sent u a pm.