KDX/KX kickstart lever swap

Joined
Mar 23, 2000
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#1
The stock lever on the '95 KDX 200 was begining to bend downward, resulting in boot slipping off the lever at the bottom of the stroke. I had read about the lever problems on the JustKDX page, and began comparing the lever on my '86 KX 125. Looked close so I gave it a try and it turned out to be a straight swap. The bent steel lever works better on the KX, boot doesn't slip off like it does on the KDX, it even looks OK.

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'86 KX125 '90 DR250 '95KDX
AMA, BJEC, TSCEC
 

canyncarvr

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Oct 14, 1999
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#2
The lever swap works ok if the splined piece is still good. Both of mine were galled/goobered/worn.

I spent a couple hours filing, fitting a piece of steel scrap, drilling for pop rivets, looking for new o-rings in my junk (read 'tool') box and then putting a 'edge' to the ridges on the lever to help keep my boots from slipping.

All that time and I'll bet'cha it'll last for a ride or two until I'm buying new pieces!!

You don't mind the shorter lever?

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  • OLD member
    'oh-oh' KDX 200
    '86 Nighthawk 700 SC
    (a motorcyle even if it doesn't have a chain!)
 

Moj

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Nov 5, 1999
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#3
What I did on my KDX when this happened(lever angling downward), was to weld a small spot on the lever where it mates with the other part when folded down. (Are you all following me? ;))

I ground it to fit perfectly. This has been a couple years ago and it's held up very well.I've also done this on a couple other bikes with excellent results.

Hey it's cheaper than a new kick starter ain't it. :)

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Moj
96 KX 250
95 KDX 200
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It ain't no fun if you're not a little scared...
 
Joined
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#4
It's all a matter of relativity... after kicking on the DR, the KDX is a snap!

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'86 KX125 '90 DR250 '95KDX
AMA, BJEC, TSCEC