Kickstarter

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Logan_H
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Kickstarter

Post by Logan_H »

So I recently bought a KDX220R, and have decided on they few things I need to tweak/replace. One of those, is the kickstarter. I was riding in an offroad park in southern Indiana, and rode down some creeks. I needed my clutch adjusted because it would kill even if it was pulled in, which isn't a big deal. Since my boots were all muddy, my boots kept sliding off the kickstarter. I looked into it and realized that when folded out, the kickstarter it's self folds back towards the rear more, instead of being perpendicular to the bike. What part do I need to replace?
pumpguy
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Kickstarter

Post by pumpguy »

Unfortunately, this is a common problem. While there are many threads here on this site dealing with kick start lever issues, they mostly deal with alternate light alloy replacements. Do a search on KICKSTARTER to see what you find.

That said, what I did is to build up the worn areas on my lever and boss with bronze torch welding (brazing) and file and grind back to original shape. That bronze build-up is pretty tough and should hold up as long as the original steel parts did.

IMO, this is not a good design, and had thought about making a fork type swivel like some other bikes use, but there's not much room, and so far, the bronze build-up repair seems to be okay.

Maybe others will chime in with other solutions to this problem.

On another subject, I sure hope your bike has an aftermarket forged piston. On 220s, the OEM cast piston is notorious for cracking and breaking up with disastrous results.

Also, be sure to get a SERVICE MANUAL. This is the most important tool you can get for this bike, and will answer just about every question that comes up.

Hope this helps. Good luck.
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Tyl3r
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Re: Kickstarter

Post by Tyl3r »

If you go here, the part you need to replace is 13061 http://www.partzilla.com/parts/search/K ... parts.html
or a link to the part itself: http://www.partzilla.com/parts/detail/k ... -1487.html

If you're buying a new knuckle, you may as well replace the kick starter arm too. Part of the reason the knuckle gets so work is because the kick start arm sticks out so far from the bike, it put a lot of force on the knuckle. If you look at the later year KX125 or KX250 kick starter arms, they don't stick out nearly as far.

You can get a KX125/250 knuckle that will fit on those splines and allow you to run one of those kicker arms. You will have to search, I can't remember exactly the years that will work, but I did find the info I needed here. I bought one of each to see which would fit nicer. The KX125 arm is pretty short, but not bad, tucks in nicely. The 250 arm is a bit longer (more preferred to me), but it hits the frame when folded in. [EDIT] Right after posting, I looked in my bookmarks and saw I had this link. Sharing is caring! https://thumpertalk.com/forums/topic/85 ... er-how-to/

Another option is the FRP kickstart arm that mounts to a stock KDX knuckle, but I don't have any experience with those, heard good things tho.
04/05 KX220 Hybrid all decked out
18 KTM 500 EXC-F Dual Sport/Sumo toy
24 KTM 300XC-W Cheater bike
Logan_H
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Country: USA

Re: Kickstarter

Post by Logan_H »

Tyl3r wrote:If you go here, the part you need to replace is 13061 http://www.partzilla.com/parts/search/K ... parts.html
or a link to the part itself: http://www.partzilla.com/parts/detail/k ... -1487.html

If you're buying a new knuckle, you may as well replace the kick starter arm too. Part of the reason the knuckle gets so work is because the kick start arm sticks out so far from the bike, it put a lot of force on the knuckle. If you look at the later year KX125 or KX250 kick starter arms, they don't stick out nearly as far.

You can get a KX125/250 knuckle that will fit on those splines and allow you to run one of those kicker arms. You will have to search, I can't remember exactly the years that will work, but I did find the info I needed here. I bought one of each to see which would fit nicer. The KX125 arm is pretty short, but not bad, tucks in nicely. The 250 arm is a bit longer (more preferred to me), but it hits the frame when folded in. [EDIT] Right after posting, I looked in my bookmarks and saw I had this link. Sharing is caring! https://thumpertalk.com/forums/topic/85 ... er-how-to/

Another option is the FRP kickstart arm that mounts to a stock KDX knuckle, but I don't have any experience with those, heard good things tho.
I will look into it, thanks for clarifying. It helps knowing what's wrong. Thanks so much!
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