Newbie starts a ground up rebuild

sir phily · Post by **sir phily** » 04:06 am Feb 12 2013

Hi guys
This my first post have been lurking around for a while got myself a 1997 kdx 200 basket case, have started a full ground up rebuild have run into a few issues bike has a few little things missing off it, the one that has got me stumped is the rear brake light switch that's mounted on the sub-frame I guess it's pulled by some sort of cable from the brake pedal I can't find it in parts manuals,
has any one got a photo of it so I know what I'm looking for,
don't no if the photos worked I'm new to all this.

Cheers Phil.
http://s1305.beta.photobucket.com/user/ ... sort=3&o=1

diymirage · Post by **diymirage** » 07:02 am Feb 12 2013

looks pretty good for a "basket case"

if i remember correctly there is a hole in the rear brake lever you just attach a wire to and the other end hooks up the switch
even better if you can attach a little spring in between

ill see if i have one mounted on my projectg bike, if i do its yours
dont hold your breath though, the previous owner installed a maier rear MX fender so theres a good chance he 86th the whole set up

rbates9 · Post by **rbates9** » 11:29 am Feb 12 2013

Where are you from? The US models didn't have a brake light switch so it could be an aftermarket switch.

sir phily · Post by **sir phily** » 12:54 pm Feb 12 2013

That makes sense I didn't think of that I'm in Australia where they come set up for full rego with brake lights & blinkers.

Post by **bufftester** » 03:53 pm Feb 12 2013

Try http://race-replica.com/kawasakiparts.htm select your year/model then look under the tab unclassified and then ignition system. Shows the brake light pull and switch I think you're looking for. Personally if I was rebuilding I'd use hydraulic switches instead. They go inline, are easy to wire, and would allow your front brake to actuate the brake lamp as well as the rear with little work. You can get them online for less than what they want for the OEM spring ($30 !

)

diymirage · Post by **diymirage** » 04:42 pm Feb 12 2013

rbates9 wrote:Where are you from? The US models didn't have a brake light switch so it could be an aftermarket switch.

i may have to disagree with you here rebate
i know for sure my plated 96 has a brake light switch which is mounted on what looks like a factory bracket

its hiding behind the right hand side cover

ill see if i cant snap you a pic tonight

sir phily · Post by **sir phily** » 05:13 pm Feb 12 2013

Thanks for that just what I was looking for was also thinking about the hydraulic one.

Cheers Phil

Post by **Julien D** » 06:47 pm Feb 12 2013

diymirage wrote:
rbates9 wrote:Where are you from? The US models didn't have a brake light switch so it could be an aftermarket switch.

i may have to disagree with you here rebate
i know for sure my plated 96 has a brake light switch which is mounted on what looks like a factory bracket

its hiding behind the right hand side cover

ill see if i cant snap you a pic tonight

No US model KDX I have ever seen has a brake light switch from the factory. If it was plated, it's likely a PO did a good job installing one in order to pass regulations in whatever state they were in to make it street legal. Would love to see a pic of your brake light switch!

diymirage · Post by **diymirage** » 09:52 pm Feb 13 2013

Julien D wrote:
diymirage wrote:
rbates9 wrote:Where are you from? The US models didn't have a brake light switch so it could be an aftermarket switch.

i may have to disagree with you here rebate
i know for sure my plated 96 has a brake light switch which is mounted on what looks like a factory bracket

its hiding behind the right hand side cover

ill see if i cant snap you a pic tonight
No US model KDX I have ever seen has a brake light switch from the factory. If it was plated, it's likely a PO did a good job installing one in order to pass regulations in whatever state they were in to make it street legal. Would love to see a pic of your brake light switch!

here you go (right side cover removed for visability)

i cant vouch for the switch being stock but the mounting bracket surely is
it was rigged up in such an odd manner i figured it HAD to be stock
the switch is a regular on/off switch that would send a signal into some electronic doohickey
(i can only assume it was some sort of a diode or something)
the single filament light bulb would light up dimly with the light on
once you hit the brake pedal the single filament would light up brighter

when i got the bike i replaced the single with a dual and just rana hot wire to the brake light switch and from there to the second filament
seemed a whole lot more sensible

Post by **bufftester** » 11:41 pm Feb 13 2013

After seeing that pic I had to go back and look at my twisted KDX frame...I had always wondered why that tab was there with nothing in it...makes perfect sense now after seeing the pic of the actuating rod/spring and switch. Learn something new every day!

sir phily · Post by **sir phily** » 02:11 am Feb 14 2013

Yep that's the same switch as on mine just missing the cable down to the brake pedal.

Cheers Phil

rbates9 · Post by **rbates9** » 06:26 pm Feb 14 2013

http://www.ebay.com/itm/NEW-GENUINE-KAW ... 73&vxp=mtr

It looks to be a pretty universal brake light switch for just about anything kawasaki put brake lights on for a long time. And being that the KDX was made as a dirt bike in some countrys and a street or dual sport in others they wouldn't make different frames missing a tab or two so the US model will still have the unused tab.

Post by **bufftester** » 07:30 pm Feb 14 2013

I think I would still prefer going with hydraulic switches to do away with that long wire that just begs to get snagged, plus it makes it easier to also wire the front brake to the brake light (required in my state), plus the switches are cheap and pretty resistant to environmental challenges. Looking forward to some pics of your rebuild!

rbates9 · Post by **rbates9** » 06:03 pm Feb 15 2013

bufftester wrote:I think I would still prefer going with hydraulic switches to do away with that long wire that just begs to get snagged, plus it makes it easier to also wire the front brake to the brake light (required in my state), plus the switches are cheap and pretty resistant to environmental challenges. Looking forward to some pics of your rebuild!

I agree to all you said.

sir phily · Post by **sir phily** » 02:08 am Feb 16 2013

Yes I think I will go the hydraulic switch found plenty on ebay, might end up a lot neater set up,
thanks guy's for the help I think I might need more advice down the track.

diymirage · Post by **diymirage** » 10:46 am Feb 16 2013

good call with the hydraulic switches
if my bike had needed a front brake light i would have used those aswell
but since the rear one was allready installed and working i just left it the way it was

sir phily · Post by **sir phily** » 08:40 pm Feb 23 2013

Getting there guy's, anyone know how to shorten a set of 2000 KX 125 forks so that I don't have them sticking so far up in the mounts.
How can I post photo's instead of just the link
Cheers Phil
http://i1305.photobucket.com/albums/s54 ... 391fad.jpg

http://i1305.photobucket.com/albums/s54 ... a98ab5.jpg

GKBO · Post by **GKBO** » 09:04 pm Feb 23 2013

When you click on your pic in PB you have a links box on the right side,click on the IMG link at the bottom of that box.When it goes yellow and says copied just come back to this or other forums and left click and paste.

And there you go.Looks good

rbates9 · Post by **rbates9** » 09:06 pm Feb 23 2013

Click on the image code I think it is and past it into the reply box and it should come up. I always have to try it a few times with the different options and use the preview button below before I get it right.

Why is the forks sticking up in the mounts an issue? If it is just cosmetic then you may find that you can get over it easier than shorting the forks.

sir phily · Post by **sir phily** » 12:47 am Feb 24 2013

No not a issue just me being fussy I think it just looks strange I guess I should get over it,
Another question I would like to keep the KDX rim so that it match's the rear is it possible to lace up a KX front hub to the KDX rim not worried about the speedo I was going to use a electric one I have to re-lace the rim any way as they all rusty, are the spokes the same length.

Thanks Guys

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