I haven't had a chance to try to install the kick assembly again since I posted the question. I think I'll try after dinner here but Eliteguy50 (thank you by the way) sent me an e-mail with pictures and his description off his af05 crank. i re-sized them so everyone can see here. I'm just glad my half moon gear isn't odd, you guys can see that the first few teeth on this gear are actually welded together. I thought I had a gear that had been messed with.
"The first 3 are of the kickstart in the natural position. the 4th is the kickstart without that kickout gear installed that turns the crank shaft over, notice how it rotates more, so that kickout gear stops the half moon from resting on the case from spring tension. The last picture is full rotation of the half moon gear, notice that I am holding the kick lever almost all the way "straight down" (as if it were installed) with my belly
'natural position':
'natural position':
'natural position':
'kickstart without that kickout gear installed that turns the crank shaft over, notice how it rotates more, so that kickout gear stops the half moon from resting on the case from spring tension.':
'full rotation of the half moon gear, notice that I am holding the kick lever almost all the way "straight down" (as if it were installed) with my belly':
![Image](http://i53.tinypic.com/2u8w6f9.jpg)