Kickstarter boss too thick-help!

Reference and discussion for the various air-cooled KDX models

Kickstarter boss too thick-help!

Postby oldman » 07:37 pm Aug 08 2017

1987 KDX200 with 240 kit--I replaced the starter shaft and gears because the starter was slipping. After I placed the kickstarter on the shaft, the nut would only screw on 2 1/2 turns before bottoming against the start lever. The width of the starter boss is 23mm. The splines for the starter boss is only 18mm. The unused 5mm extends onto the threaded end of the shaft. I wonder if my start lever is not the original that came from factory (poor design) or if a previous owner installed the incorrect lever. The IPB drawing of the lever looks like what I have. The nut installed on old shaft will turn 3 1/2 turns-(still too little). Anybody else have this issue?
Still looking for a decent rear fender for a decent price.
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Re: Kickstarter boss too thick-help!

Postby Jason » 11:10 pm Aug 08 2017

Are you able to post a picture?
Thank you, Julien D for all your hard work!
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Re: Kickstarter boss too thick-help!

Postby oldman » 08:44 pm Aug 09 2017

I sort of solved the problem. I used a bench grinder to grind down the side of boss (closest to motor) so that I can tighten nut to 4 or 5 turns of the nut/shaft. This still leaves no room for a washer. The nut is in contact with the boss and maybe 2 threads on the nut not used.
I found a new rear fender for $81, but will look some more to try to find a better price.
I noticed today that the shift return spring is either broken or slipped off. The lever must be pushed back down after each up-shift. I hope that the spring is behind the right side cover so I dont have to split cases.
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Re: Kickstarter boss too thick-help!

Postby Jason » 10:58 pm Aug 09 2017

Something does not sound right on the kickstart knuckle. Maybe someone used a different model.

Look on eBay or dcvmx for a fender.

If the spring is off, it won't be in the gearbox.
Thank you, Julien D for all your hard work!
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