I had to pull the right side cover off my 2004 TE250 to repair a starter gear issue and upon reassembly I find that the kickstart lever wont return when kicked. When I looson the cover again it goes back fine. I have rechecked it several times and can't find the culprit. On the kickstart shaft I have a bushing and a very thin washer underneath the spring. Dos anyone know if I am missing something? I have found a couple of posts with similar issues but no definite solution.

Thanks for any help you have.

The spring is being bound or pinched when you put it together. Take it apart and make sure the spring is centered as well as can be on the shaft and carefully reassemble. I had the same problem and was that was the cure.

Hi ,
yes -it sounds like the spring is being pinched.. are you 100% sure that the parts are in the correct place / order ?,,

there were a few " how -to " retrofit kicker threads for the  250 /450 back in the 2004/ 6 era, with pics,
maybe worth a SEARCH ,

Charlie

Thanks guys, I found the notch in the bushing wasn't engaged on the spring where it goes into the shaft, all good now. I never would have even looked back there if I hadn't read another post from George that mentioned it.