I just bought my 10 year old son a 1975 KD100M bike. He's been all smiles for the last couple of weeks, but today the kick starter is just slipping and not engaging the engine. If we kick it over slowly, it will turn it over, but if we kick it hard it just slips and doesn't turn it over.

I've taken the right side apart, but can't seem to figure out what needs to be replaced... Are there any downloadable service manuals or advice anyone has for us?

Thanks in advance for a newbie question...

Steve B

 

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Hey Steve welcome to the forums, I would take it apart again, there will be something obvious in there that's not right. Pull the spark plug so it turns over easier, and watch the slow kick that engages and then watch as you do it faster and it doesn't engage. I'm sure there is something in there that can be easily fixed.

 

I took the side of the engine off on the kick start side, but can't see anything in there... It looks to me like I'm going to have to pull the engine and split the crankcase... YUCK!!!!!

Someone please tell me that I don't have to pull the engine and split the crank.

Steve

 

get the manual.....good luck and welcome to kf.

 

Well, I needed to pull the engine and split the crankcase to get to the problem. There is a little rectangular pawl that comes out and engages a gear when the kick starter is pushed down.

The pawl was worn (or broken) where it contacted the teeth of the gear. I took a welder and built it back up, ground it down smooth and tested it. Works great now.

Just waiting for an engine gasket kit to come so I can get it all back together.

Steve