is my shifter lever bent?

[MoonStomper]

2003 KDX 200
While servicing and inspecting the mounting interface between my shift lever and the motor the other day I noticed that the end of the lever has a bend in it. Does that look right. When viewed from above it appears the folding tip is forward of perpendicular from the direction of the bike's travel. Any thoughts? Sorry - I just thought of asking this question and don't have a better picture. Thanks for your input!

InkedKDXcarb-10-2020-adj_LI.jpg (785.55 KiB) Viewed 3137 times

[KDXGarage]

yep, it's bent

non-OEM fuel hose's non-OEM clamp is off too

and that front sprocket makes me want to see a straight-on picture :-)

Also, since you are racing, look into running "just" the metal guard on the front sprocket and not the plastic one. They can be a grass and mud catcher.

[sarrant]

Also, since you are racing, look into running "just" the metal guard on the front sprocket and not the plastic one. They can be a grass and mud catcher.

But how will he know what order the gears are in?

[KDXGarage]

I use a hand written note from my mom, taped to the crossbar pad.

[Goat]

Must be nice to come from an MX family! Now I finally know why none of the other guys are leaning over their left foot like me, heading into that table top.

[KDXGarage]

Guys on the side of the track..."He is about to rip a badass whip over that jump"

Inside Goat's head...thiiirrrrd

[Goat]

Haha! That’s it.

[MoonStomper]

yep, it's bent ... non-OEM fuel hose's non-OEM clamp is off too .... and that front sprocket makes me want to see a straight-on picture :-)
Also, since you are racing, look into running "just" the metal guard on the front sprocket and not the plastic one. They can be a grass and mud catcher.

Yeah I was in the middle of pulling my carb when I took that shot so I knew about the fitting. Actually about to install a blue Tygon fuel hose too. That guard DOES collect a lot of grass and debris! Does anyone have a picture of the alternative you suggest or another superior chain guard that will fit?

I'll torch that bend and tap her into line - thanks for the verification!!!

[KDXGarage]

Take the lever off before hitting it, just in case you had not planned it that way.

I asume shorter bolts might be called for on running just the metal guard.

[MoonStomper]

yep, it's bent ... non-OEM fuel hose's non-OEM clamp is off too .... and that front sprocket makes me want to see a straight-on picture :-)
Also, since you are racing, look into running "just" the metal guard on the front sprocket and not the plastic one. They can be a grass and mud catcher.

Yeah I was in the middle of pulling my carb when I took that shot so I knew about the fitting. Actually about to install a blue Tygon fuel hose too. That guard DOES collect a lot of grass and debris! Does anyone have a picture of the alternative you suggest or another superior chain guard that will fit?

I'll torch that bend and tap her into line - thanks for the verification!!!

So I took the plastic 'grass catcher' off and used shorter bolts to keep the steel guard in place - I like it much better. Rode all evening in the woods and fields, got home, NO GRASS! I also bent the the shifter back into alignment (yes I took it off first!). Mucho bettero.

[Goat]

I need to try that too. I can just tape the plastic piece to the x-bar, so 2 benefits!

[KDXGarage]

Good job on getting it more to your liking and the lever.

[Goat]

I went to do the high tech chain cover mod, and found a loose shifter. When I went to snug it down, I found why it was loose. Of course the was at 10pm, day before a race.

[Goat]

Removing the plastic cover would be more useful if I could avoid dumping it in the mud pit on left side. But it did help some.
Ps. I did tape up my wires.... after realizing KDXG would ask when I was gonna shape up.

[MoonStomper]

There has got to be a better way to cover the gap exposing the wires. Something better than electrical tape, wonder of silicone tape would be better? Might try that.

[doakley]

I think the shifter breaking there is fairly common. I had mine welded but it didn’t hold. Only solution I found was a new lever.

[KDXGarage]

Goat, sorry to see the shifter let go at a bad time. If you are racing, hand and feet levers are handy spares.

Excellent choice on front sprocket there! (and taping)

[Goat]

I welded it, and it made it thru the race. But I don’t trust it, so will be shopping for another and keep this for spare.
I also broke off my front brake lever so need a couple of those for the kit.
I have some self fusing tape (kind of like what we use on airplanes), but didn’t have it with me. I think it will do the trick for those wires.

[doakley]

There has got to be a better way to cover the gap exposing the wires. Something better than electrical tape, wonder of silicone tape would be better? Might try that.

I used a bit of RTV to seal that.

[MoonStomper]

There has got to be a better way to cover the gap exposing the wires. Something better than electrical tape, wonder of silicone tape would be better? Might try that.

I used a bit of RTV to seal that.

Hey Doug - Thanks on the RTV idea, I'll try that tonight. BTW, I finally got to read through a lot of your Nat'l Endurance posts, very cool stuff and I enjoy your writing style. Quite frankly, you provide a gold mine of KDX info, experience and information in there. I'm interested in trying that Endurance racing as a contrast to the HS. Was damn sorry to read about your wreck, I hope you are healing up fast. I don't know what your current plans are as far as racing or riding again, but hope you find the will to continue riding that KDX somehow. It's amazing what I've seen in mountain biking over the years - guys riding with one eye, arm or leg. There has certainly got to be a brace that could be designed to support your injured pelvis and enable you to get on. Whatever you do, take your time and think it through, don't make any rash decisions. Us old guys gotta keep plugging along somehow, these young whipper snappers need our inspiration!

Seriously, really appreciate all you have done on this site, a lot of your input on others' queries has really helped me get my bike sorted and saved me a lot of money and time.
Keep rockin' brother!
Ben