Stevo, hi from a couple of Counties away. I don't have any experience of either your trans or kicker kit, but have owned a kickstart Harley for many years. There is a bronze bushing in the kicker mechanism which, if it comes loose and moves, can prevent the two halves of the kicker engagement dogs from fully engaging. I haven't suffered any injury, but have had a similar experience as you on a '74 FX1200.

 

Ouch! Go back to original equipment and don't jump on it.

 

 

Pull the kicker cover and look at the innards. See what might look worn or misaligned and instead of replacing some parts you might consider installing a different kicker set up. I'm not real sure of the quality of the Chrome Specialties kicker.

 

Has it ever worked correctly, or is this a new install?

 

 

I get that, but what I'm asking is if was reliable for a meaningful period of time and only later started acting up, or if it was this way from the start.

 

There's a brass bushing in those cheap kits that wobbles out very quickly that gives the problems you are having, also the extension that goes on the end of the mainshaft that gear rides on has a tendency to strip the threads and allows things to move on you, cover has to come off for a look see anyway. Installed a lot of those kits way back when and most had these issues sooner or later if they were used regular. Only Bakers is rock solid but it isn't cheap.