1. Why is the initial kick down require a bit of pressure? It seems like its locked up but when you stand up on it it goes and fires right up. I'm used to an older kicker that moves pretty easily. The TW seems to need a hard push for the first 1/2 inch of movement and then it goes. Is it just the compression stroke holding it back at first? This would imply it always ends up back at the compression stroke when turning it off because it does it every time. It makes sense to me that the engine when turned off would probably end up near the compression stroke because the pressure would stop the engine when its just about stopped. But I wanted to ask. I plan on pulling the plug and kicking it to see if its easier and that I dont have a bind of somesort going on.
I believe the pressure is due to the kicker gear being engaged. I have no idea if mine is smoother/easier from when I first installed the kick start. If all is works well and no unusual noises while it's running after the first couple miles I'd call it good.
2. Why does the kicker hit the foot pedal attachment on the end of the stroke? Not hard but it does. Is this normal?
Normal, was just covered in a different forum thread. All answers were that this is normal, even for other bikes.
3. I had to drill out the non kick start plug in the case and then pop it out with a screwdriver. It would come out on its own. Anyone else have this issue?
I popped that plug out from the inside of the case, don't recall it being difficult but it's been awhile since I did the install.
4. Why cant you re-use the clutch lock washer if its in good shape? I was able to bend mine back in shape and it seems like you could re-use it. I didn't but was wondering, is there a reason you must replace it?
You could re-use it. But to replace it is one of those cheap insurances that's recommended to people. Bend something enough and it'll break, and you don't want that piece loose inside with a potential of lodging itself between gear teeth or its shrapnel floating around inside the oil. When someone can't trust their own discretion whether it's still good or not, it's easier to tell them to just buy a new lock washer than to fret over whether it will break off.