I just tried to put mine on my '01 KDX200 lastnight. I don't think it's the best set-up in the world. I like hydraulic switches, but there's just no room for one on the KDX. Baja Designs sells a micro-switch for the KDX. If I had to do it again, I'd go that way (story of my life!).
Anyway, Jeff admits it's a very sloppy fit. I was thinking about putting a nylon nut above and below the bracket with washers to hold it in place better, but I really don't think it matters that it's loose. The wire will hold it in place and if and when the wire breaks, the electrical connections SHOULD hold it in place for a while. I'd probably zip tie the electrical wires to the frame just in case.
I WOULD take WOODSRIDER'S advice on putting a spring somewhere along the wire. There really is nothing from keeping the switch from being torn apart under heavy braking if it's not adjusted just right. You may think you have enough slack by just pushing the pedal with your hand when adjusting the switch, but you never know how far it's going when you are braking hard. You'll need to find a spring that is stiff enough to pull the switch, yet soft enough to stretch a little when the switch bottoms out and the brake pedal keeps going down.
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[This message has been edited by Russ (edited 04-14-2001).]