2004 KX500 Kickstarter/other Help

[jason93]

I’m hoping you guys can help narrow my path on this Kickstarter issue I got today on one of my kx500s. My 04 is a nice tight motor and runs great, I went to a practice track today did 8 laps to learn the track and had arm pump so I pulled off to take a break. As I drove back to the stand the bike let out a really odd backfire/pop. So I take 20 minutes then go to start the bike and when I kick down the Kickstarter doesn’t return, and it’s not hanging on the foot peg. I can take my foot and lift it up. It’s not slipping just goes down and won’t return.

Normally I’d think it was the return spring but now I’m thinking it may be lower end or something else because the bike hasnt started since that pop. Figured I’d ask here before I tear into it. I’ll look at it again tomorrow and see what I find. Any ideas?

Much appreciated.

[Sandblaster]

Sounds to me that you have two issues.
A broke return spring and a electrical issue,
But what electrical issue?
Almost sounds like a sheared flywheel key.
But start simple... fix the return spring,
Then disconnect the kill switch and try to start it.
Then, replace the plug...
If it is sparking good check that key...
Post what you find..

[jason93]

Thank you Sandblaster, I will try this in the morning. Many thanks.

[jason93]

You were right... keyway sheared off. Wow these keyways are really small compared to the Honda 500. I think some lapping is in order. Sandblaster, thank you again so much for the info l, super helpful and spot on with the diagnosis.

Many thanks.

[Sandblaster]

Sometimes I get lucky