KDXRIDER.NET

I agree with you, David. I had widened my pegs with a welded on extension on the rear, but the extensions prevented the kicker from getting enough throw, because of the "delayed" engagement you speak of. I could still start the bike, but when it was cold, I wanted that extra little bit of rotation. I ended up rotating my kicker forward one spline on the shaft, but then the very tip of the kicker would contact my pipe.
Someday, I will take my clutch cover off and see if there is a way to get it to engage sooner, but I suspect that it all has to do with the coarse teeth on the ratchet mechanism.
As far as the short vs. long kicker goes, I don't mind the long one, and it really helps when I am really tired. The long one does make it difficult to get my foot on top of it when I am stalled in an awkward position, though.
I have welded up many kick start bosses, and most can be saved with a little weld and grind job.

David_L6 wrote:While I'm not really interested in changing the kick start lever to a different length, I do have a question that, hopefully, someone here can answer...

The kick starter on my KDX doesn't engage until the lever is about half way down. It doesn't catch up at the top like every other bike I've ever had did / does. It works and starts the bike just fine it's just strange that the lever is already half way through it's stroke before it starts turning the motor. Anyone know why it does that?

I've been wondering the same thing. Are all KDX's like this, or does mine have an issue? I rebuilt my '94 KDX for my GF, it's a great bike, but she really struggles to start it. I have to improve this situation.

This is a great write up, i decided to do it after reading this as mine was buggered and I slip off it every time i try to kick it.
I went down to my local kawasaki and they quoted me $199 for the kicker and said I'd need to buy the whole unit of the 250 one to get the knuckle off! Thats $400!!!!!!
I went to the wreckers (2 different ones) and they said the kx 125 kickers were rare as rocking horse sh*t as they break.... So is there a cheaper alternative here in Oz? I can't find them on ebay.... Cheers.

I got my lever on eBay, and you can get just the boss from Kawasaki. I posted the part numbers above.

Oh ok sweet cheers. I'll keep looking on ebay and keep my eyes pealed thanks

mcgark84 wrote:This is a great write up, i decided to do it after reading this as mine was buggered and I slip off it every time i try to kick it.
I went down to my local kawasaki and they quoted me $199 for the kicker and said I'd need to buy the whole unit of the 250 one to get the knuckle off! Thats $400!!!!!!
I went to the wreckers (2 different ones) and they said the kx 125 kickers were rare as rocking horse sh*t as they break.... So is there a cheaper alternative here in Oz? I can't find them on ebay.... Cheers.

They don't call 'em Stealerships for nothin'.
I just added everything up on Ron Ayers, total $125.60 for all parts before shipping. KX125 lever, all the small parts that go with the lever (including the grease seal), and KX250 boss.

Edit: I just noticed your from Australia, so I don't know if RA will ship to Oz, but worth a look to see.

Great write up Nick.

I'm gonna give that a try. I've always thought you stab a two stroke to life and kick a four stroke.

As far a starting by hand... forgetaboutit.

How does this kicker go with a hybrid. My standard one is looser than a $5 hooker and was looking at either this or a straight KX250 kicker. Thoughts??? I am worried about frame clearance..

If the hybrid is based on the KX125 frame you should probably go with the KX125 lever on the 250 boss. I bet the 250 lever would be too long.

Has anyone tried one off a kx250f?

Never heard of anyone doing it but can't say for sure if it would work or not. Trial and error.

I have a 2003 Hybrid, with a KX250 kicker. It fits and work fine.

Two stroke or four stroke kx250?

I have a 2003 KX 125 frame a 2004 KDX220 motor and a complete 1999 KX250 2 stroke kickstart lever. It is longer than stock. I rotated the kicker 1 or 2 splines forward on the shaft, and it fits in neatly between the frame and the pipe. I might have used a file on the knuckle between the knuckle and case. I can't remember. I have no trouble starting the bike. I am on the tall side 6'2" tall. It works very well, and looks like it was made for the bike.

Hockeyboysomers - Do you have a picture of your KX250 lever on your 2004 KDX? I assume you mean you replaced the lever and the boss??? Thanks in advance.

I've got a kx250 kick start boss and lever on my 92 dx200. Fits great, the lever is pretty long and lands beside the exhaust when it's tucked away, but it's a good inch or two away and never contacts the exhaust. Starts easy, I'm happy. I'll see if I can post some pics.

Fun Wheel Drive

i have a kx250 kicker lever but no boss....wonder if theres a boss that'll let me use the kicklever on our kdx250 hybrid?

Can anyone tell me if a 1990 - 1994, or 1995 - 1998 KX250 knuckle / boss will work also? I bought a 1990 KX 125 kick start lever because it was of the same style as the late 90s and 2000's, as opposed to the 1989 and earlier which is the same sealed style as the KDX with the clip and O-rings with the open-top.

Just did that to my 03. Seems to be just fine

2022 mod UPDATE…

After endeavoring to undertake this nifty upgrade I ordered the 250’s boss and the 125’s lever assembly from RMATVMC. The 125 kick lever is not available as a separate item new, but the assembly comes pre-assembled with the grease seal place. I ordered the extra grease seal for future maintenance.
There was an issue with my matchup that required some extra elbow grease beyond what was noted above…

I found after inserting the 250 boss into the kick lever that the retaining shoulder screw would not fully reinsert.

Close comparison and examination of the two bosses revealed that the retaining channels did not quite match. Reinserting and using a light I could see the problem was at the top edge. It was close enough that a 11/64” chainsaw file carefully applied to the upper inside channel of the boss - along the range of motion across where the retaining shoulder bolt sits as the lever rotates - allowed for the proper fit.

If you don’t do this, but try to force it, you will strip your bolt threads.

After a number of passes with the file and refittings, everything finally fit properly. One more note: I also run the green plastic frame guards. Rather than filing back the heal of the kicker I just removed a little plastic with my solder iron till it passed by cleanly.
Thanks to Slick_Nick for his work in the original post and help finding it for me.