What happens if the character I bring back from the KO area ends up with enough damage counters to KO it?

Both characters will end up KO’d, but the character that started in the KO area will be on the battlefield for a short time. For example, any ability that triggers when Upgrades are moved onto that character will still happen. If that character has any revenge abilities, those abilities will also happen.

Involuntary Promotion: if I play it and chose a tapped character, does the revived character come back tapped or untapped?

Untapped.

If I have a character with Bumpers attached, and I play Involuntary Promotion on a car in my KO area, does the returned character receive the Bumpers in time to prevent the damage counters from being moved?

The damage and upgrades are moved at the same time. Bumpers’ effect won’t stop the damage counters from being moved.

Can I KO a Battle Master with Involuntary Promotion if I have no bots in my KO area?

Yes. If you have no characters in KO or the characters in your KO area have too many stars, you can use Involuntary Promotion to KO one of your characters.

Regarding Involuntary Promotion trigger timings, when I shift the upgrade and damage counters to the returned character. Do I get to choose to shift the damage counters first followed by the upgrades since they are both my triggers?

No part of Involuntary Promotion is a triggered ability. The instructions are all followed in order and the damage counters and upgrades are moved at the same time.

Does Involuntary Promotion count as "repairing" the resurrected character? In other words, could Torox or Ratchet benefit from its play?

No. The character appears on the Battlefield fully repaired. It’s not repaired while on the Battlefield.

Can you I Still Function a character with a Body mode?

You can't bring back a Body mode character from KO because it won't have a head. Effects like I Still Function! and Involuntary Promotion will not work at all to bring back a Body. You can, however, bring back a Head from KO because it will be in Bot mode (and only in Bot mode).

Why can’t I bring Dirge back from my KO area?

Dirge has the ability to bring back a Blank card when KO’d, we did not want to create any “infinite loop” type scenario with the character due to cards like I Still Function and Involuntary Promotion.

What happens if my Snapdragon is in Alt mode and my opponent plays Involuntary Promotion?

The character brought back from their KO will stay fully repaired because no damage can be moved to it, but the Upgrades from the original character will move as normal.