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I’m currently rebuilding my 1989 kdx200 engine. I finally got around to removing the transmission shafts and gears and noticed the kickstart idle gear bushing is worn enough to let the gear move quite a bit. The shaft measures 14.96 mm and the I.d. Of the bush at 15.06mm so .1mm difference so .05mm clearance. Is that too much and has anyone replaced just the bushing? I don’t really feel like buying a new gear with bush for $70 when the bush is easily replaced. Has anyone replaced this bushing?

Never had to but it shouldn't be that bad to do so.

I've not seen a source for the bushing, but if you're talking about the idler gear on the kickstart shaft that engages with the spur shaft (part number 59051-1309 here) IIWM I'd not worry too much about it if it hasn't been causing problems.

That is indeed the one. I bought a newer used one off ebay for around $20. Ill see how that one fits compared to the old one, maybe they just have that much radial play?

I've not spec'd mine, but it has always felt a bit loose whenever I was in the motor.

The bushing in my newer gear measures at 15mm. Definitely a better fit with much less play.

Is that the one that looks somewhat like swiss cheese on the inside??

Yeah that is the one. while searching for a replacement bushing i didn't come across any bushings that looked similar.