Need some help diagnosing kick start slip

[Ryah]

I've got an 85 250r that I recently rebuilt the entire engine in. I was extremely careful to make sure I kept track of all the parts. However when it came time to reassemble the kickstarter I couldn't find the one washer that goes against the outside clutch cover. I assumed that I must have lost it, so oredered a new one. Now the kickstarter slips some times (ie it goes to footpegs without any resistance). I know that my clutch cover was replaced because it says $45.00 on the inside. My question is, if this clutch cover was from an 86 or newer should I get rid of that spacer (It shows that it was not in the 86 250r motor). Could this be my problem. If not any other ideas. As always, I appreciate any comments.

[metalm0]

What do you mena by it slips without resistance though? Could it be kickstart shaft is worn? I dont understand what you are truly stating.

[Ryah]

No parts are worn. Everything is in excellent condition. My thoughts are that the washer is not letting the kickstart gear engage far enough to the clutch basket gear because of the extra width of the washer. I'm making the assumption that the 86r motor and up had the extra thickness of the washer already built into the case where the kickstarter shaft goes thru.

[clutchcargo]

Not that it's any help, but I had an 85 250R in 1985 and mine did that when it was new. Honda had a recall on it and the dealer ate the cost. It was a quick fix, but I don't know what the repair consisted of. I think it was a gear swap, but I can't say for sure.

[deathman53]

I had the kicker slipping in one of my 250r's, I replaced the kicker gears, they may not look worn, but it doesn't take much for them to slip. Is one of the springs worn or possible did you put back the spring holder/tensioner right. I know mine had to go a certain way or else it didn't catch. The spacer is required for 85-87 250r motors and the 88/89 motors had part of the spacer built-into the kicker shaft and the bulge in the cluth cover, it didn't use a spacer. I have a 88/89 cover on a 86 motor and I had to use a spacer that came with a hinson cover.