Scooterotica

Trying to kick off the P200, it does turn over but any pressure on and it slips. It doesn't feel the same as a clutch cutting through butter feeling, it's clicking from the kickstart side. I checked the clutch that's all fine so i split the case. I couldn't see anything wrong here but I'm guessing the small kickstart gear it the problem? Looking at it it doesn't look worn? The scoot only has 2,500 miles on the clock but I guessing someone held the kickstart down wearing the kickstart gear down but I thought I'd see wear? I can't think it could be anything else???

I had similar problem and did like you, ie split casing, replaced kick start cog and new coiled thrust spring, but still same problem. After more help from this forum, turned out that clutch Woodruff key had sheared. In the end put a new clutch in, but from my new experience with vespas, adjusting a vespa clutch is a fine balance. Get the cable too tight and kick start slips like you suggest. Too slack and it drags. To summarize, I feel that your problem lies with your clutch.
See my same issue in this link, before I learnt it was the clutch. Good luck. http://scooterotica.org/forum/viewtopic.php?f=8&t=29549

Thanks for the input. I did check to woodruff key on the clutch and it's okay. I took the clutch off and put another one in for good measure. I was hoping it was the clutch and went there first but all that's fine. Apparently, the kickstart gear is the second highest failure rate after the cruciform but I wish i could see wear on it somehow. The worry is putting all back togther and having the same problem.

Have you checked that it's not just the splines on the kickstart that have worn ?

It was the gear start cog. Comparing between the two - old and new cog, I couldn't see the wear on the old one. Anyway, that was it just got to get it to start now, damn thing.

Theres two types !!!! early and later be sure and use the right one as the wrong one will turn crudely on the primary drive pushing it sideways and crack the casing where the primary bolts in!!!!!!!!