KTM 495 kick start not engaging

[Blackjack]

https://youtu.be/lLCXkz52IRk

Freshly rebuilt and Kickstart is not engaging.  Return spring is still working. Don't want to have to split the cases but not looking good.  Any suggestions what has gone wrong here?

[Oldfart]

I can only speak for Suzuki ... you have to line up the dots on shaft and gears, for it to work properly.  ie  gear is held against stop to dis-engage.

[oz555ktm]

Need to check spring broken or moved from where it shoud be .

and the Space between the Teeth  may need shimming up to reduce the Gap ...

[Blackjack]

I should point out it was working well after rebuild.
Just after a weekends riding it failed.
The starter wheel or ratchet gear are not engaging.
Next step is to pull clutch out so i can get to starter gear see if there is anything obvious but anything other than that its internal

[gra1961]

you wont have to split the cases as it is all on the clutch side the kick start has nothing to do with the gear cluster

[Blackjack]

Thanks gra1961 but the kick starter gear sits in a well and the selector shaft sits above the gear. So you 'should' have to split cases to rebuild.
The ratchet gear jumped the stop screw and rounded the lip off the recess on the ratchet gear where it catches the stop screw. It was tricky but it is working again for now but suspect it will happen again so need to track down another ratchet gear

[oz555ktm]

This Photo Mite Help..

Check to shape of the spring and the Lug on spring...

[Blackjack]

This is the worn area, hard to tell but the gear in the photo looks much worse.  Was also missing the large washer so there might of been a bit of excess play as well.

[Oldfart]

Tells me you are not dis- engaging as per note in manual