Suzuki 2 Strokes

Hi all I am new to the forum and needing help. I have just rebuilt my 380 and can't seem to set the kick start return tension, I line the dots tension the spring fit the cog and all works fine until I refit the outer case then it won't return, I hope I am just doing it wrong, any ideas ? All keep safe and well thanks

Should be similar to the GT550 we did recently.

See parts diagram: https://www.partzilla.com/catalog/suzuk ... ck-starter

You need to preload the spring (part # 15).
With cover off & kick start lever on, slide kick starter (part # 2) out so it clears the stopper (part # 9).
Use lever to preload the spring until the kick starter goes past the stopper.
Slide the kick starter back in & let the starter rest against the stopper.