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Thread: 85 200x Kick start issues after kit

  1. #1
    Join Date
    Sep 2020
    Location
    Texas
    --
    11

    85 200x Kick start issues after kit

    Hello all,

    I have a 1985 honda atc 200x that has the well known slipping kick starter issue.

    I was able to track down one of the kits that replaces the two starter gears & spring. After replacing all three items and getting the engine all back together it is still constantly slipping.

    It slips bad enough i have extreme trouble getting it started. The kick lever usually moves about halfway down before it seems to engage & can be lowered that far very easily. Maybe with one finger. My foot usually hits the ground when completing the kick.

    Any ideas? Thank y'all for the help

  2. #2
    Join Date
    Nov 2019
    Location
    Florida
    --
    1,044
    Did you take any pictures of the new vs old gears? side by side maybe?
    I would be interested to see the differences, also could the spring not be seated correctly? therefore not meshing the gears firmly enough?
    I have replaced the spring only in my 84, It did not help.

    Thanks
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  3. #3
    Join Date
    Jul 2005
    Location
    Manheim, PA
    --
    5,742
    gotta back cut gears, use a spacer, use a heavy duty washer. buying and over paying for a kit now days is over. the higher the compression motor the more you see this. Ive seen it on XR200's also.

  4. #4
    Join Date
    Aug 2020
    Location
    florida
    --
    58
    Quote Originally Posted by oldskool83 View Post
    gotta back cut gears, use a spacer, use a heavy duty washer. buying and over paying for a kit now days is over. the higher the compression motor the more you see this. Ive seen it on XR200's also.

    I think your problem is the 2 outer gears that the kick lever goes to is installed wrong. They are the 2 gears under the small outer cover that the shaft comes thru. They are 2 small dimples that lines up. I think they are some videos showing had its done. I back cut my gears and installed a stronger spring and never had anymore problems until i sold it, Mine was a 84.

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