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RE: 1995 KDX200 - Kickstart Repair
Last weekend my fine machine started the 1/2 - kick issue (Slip / slipping / catch / spring). And I think I am starting to wear out the lever boss with my mini kicks (when its cold).
Since I will be out of pocket for next 3 days, I am considering to order the parts ahead of time and throw the money at it, rather than do proper investigation first & make a hangar queen for this weekend.

If anyone has done this recently, can you please check me if these look right:
92081-1926 Kicker Spring - $12.18
13078-1063 Ratchet Gear - $65.22
59051-1224 Spur Gear - $100.35
92081-122 Ratchet Spring - $6.62

The diagram also shows another Spur Gear that i am not sure if needed to fix this or maybe is alternative to regular Spur Gear.
Is this also something I may need?
59051-1309 Spur Gear, 30T - $72.55

Revzilla Diagram:

Damn. I think I would try a new spring and sanding / filing the teeth before letting go of that much money.

13078 and 59051 in the diagram, not 59051A. Look at the two with the teeth to engage and slide over each other.

I probably will try that. My wallet started yelling at me. Ty!

The metal is super tough, so good luck!

Yeah, check the pawls on your ratcheting gears and make sure they aren't rounded off. Usually the failure is the spring losing tension or the smaller gear teeth rounding off. You can use a file to sharpen the edges of the teeth. The only spring you need is the 92081A, the other is your return spring, so if your lever is snapping all the way back it is fine.

Cool. I’ll at least get that one on the way. Ty.

Anyone know if E and H use the same spur and ratchet gear?

*edit* Looks like no for an 89. 90 and up have a different part number. I have a set in good condition from my 89.

I bought kicker boss, spring, ratchet gear, gasket.
Kicker boss fixed it back to 90%+ good and another stellar 1/2-kick dead bike 2nd gear start, at last race.
So I will be waiting until winter or I have another reason to pull it apart to do the complete job.
Thanks for the help!

How worn were the teeth when you pulled it apart? Mine was slipping terribly, but with some time and a diamond file, I got the teeth sharp again, and put in a new pressure spring. Now it kicks like it did brand new!

Slick Nick, do you know which exact file you used (link to research/buy maybe)? Yours looks to have turned out great.

I did not take mine apart yet. Straightening out the kick
Lever alignment (and changing trans oil 3 rides in a row) seems to have it working good. But for sure it’s not like brand new.

KDXGarage wrote: 09:42 am May 21 2021 Slick Nick, do you know which exact file you used (link to research/buy maybe)? Yours looks to have turned out great.

Sorry I don't. It's been in my toolbox for 15 something years. It's just a triangle edge file, maybe a jewelers file?

Thanks, Slick NIck.

I got the kicker parts in and finally all back together.
Works good!
But I picked up a leak around the big clutch cover gasket, near the rear.
I think I will need to pull it apart and start over.
Do y’all have a favorite gasket helper goo that you like?
I used black form-a-gasket on 1 side of new gasket (like I usually do).
But am thinking maybe to try silicone on both side this time.
Any thoughts?
Thank you.

You shouldn't ever use silicone on a dirt bike. If you really need a sealant then use Indian Head or similar.

I had not heard of that (Indian Head) before.
When I pull it apart I will try to see if I made some mistake… but sure seems like everything fit together properly.
The Indian Head maybe will help.

I have always run those gaskets dry and not had a problem as long as the mating surfaces are good.

bufftester wrote: 07:55 pm Sep 10 2021 I have always run those gaskets dry and not had a problem as long as the mating surfaces are good.

Yup, same here. If I do use anything, because I plan to be in it again many times, I only use grease and nothing else.

On closer inspection. It’s not likely a gasket sealing exactly.
I probably have a hairline crack in the clutch cover and would need to use a paint on sealer over the area, like the pre-existing condition.
Any idea what that white stuff bottom might be? I will keep an eye on the drip, and if gets too annoying will see if I can do something similar.