KX 125 aluminum kick start lever installed!

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KX 125 aluminum kick start lever installed!

Postby Bailey28 » 09:17 am May 04 2006

I just got done installing an aluminum kick lever on my 05-200. I think I saved at least one lb. over the stock steelie. Lever tucks in nicely too. I had to take apart both levers and use the bottom splined part from the KDX. I also had to machine a small channel for the phillips screw to ride in.

I would post a pic, but I don't think I have the space or capability to do so. I need a volunteer... would someone be willing to post a pic if I sent you an email with the pic attached?
FAZ
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Postby m0rie » 09:23 am May 04 2006

Why don't you use the gallery here?
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Postby canyncarvr » 10:55 am May 04 2006

All sorts of folks have aluminium kickers. Maybe from FRP, maybe off a KX..but it's commonly done.

A note of caution when doing such: Yes, you have to use the KDX knuckle, but if you use a used knuckle, IT may well be shot (worn out) in which case putting your maybe brandy new lever on a used knuckle is not going to work.

You will end up ruining the brandy new lever.


I didn't machine anything for any phillips-headed screw though. Ooops! :wink:

BTW...the detent spring on the OEM kicker is a piece of junk. It is made evidently from the same dyn-o-mite quality metal as is the kicker. It's likely collapsed. Go to your local hardware store and get a real spring.

Put the retaining allen in with some thread locker.

You can use one-each o-rings from the same hardware store, too.
**edit**

Ooops summore. You have to use TWO each of those o-rings...not one!

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Postby Wudscrasher » 05:48 pm May 04 2006

If any of you could post a pic, I'd like to see it. Since I'm an imposing 5'6" with boots on, a shorter lever for me to get my shorty leg up on to kick it over would be great! I saw a post somewhere about using a KX80 kicker, can't remember where...

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Postby canyncarvr » 06:00 pm May 04 2006

What is it you would like to see? A studio pic of a short kicker installed on a showroom race bike?

Image


...or just the lever? (this one from FRP)

Image


The useable KX part is from an '89 KX125.

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Postby Colorado Mike » 09:07 pm May 04 2006

Speaking of short stuff from other bikes. I mangled my shift lever and bent it back so many times it was a pain in the butt to use. I was missing shifts a lot and needed to swap it out. I grabbed the one off my kids KX85, and it works great. Keep in mind i have a 12 tooth CS sprocket. a 13 might still work, but barely. Oh, My kid's leg is broke, so he ain't riding anyhow.
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Postby Bailey28 » 09:44 pm May 04 2006

CC,

I used on from a 97 KX 125, the top of it is fully enclosed and doesnt use a cirlip or anything. The large phllips screw holds the thing in place from slipping off of the KDX shaft. I only had a few thousandths of an inch clearance but I managed nicely. I'll see if I can get the gallery to work for the pic
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Postby Bailey28 » 09:58 pm May 04 2006

Guys, look in the gallery, I just added two pics.
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Postby KDXer » 02:11 am May 05 2006

For the lazy peeps.

Image

Image

Now where's the rest of the bike ?? ;)

BTW Have you even ridden that puppy ?? Looking at the sticker on the exhaust and lack of wear to the frame paint I would say twice if it's lucky.
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Postby gtoron » 10:13 am May 05 2006

How much are those levers?
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Postby Wudscrasher » 10:21 am May 05 2006

Looks good! Are there certain model years for the KX125s that the kicker won't fit a 2000 KDX220? What are the limiting factors for making a part (the kicker) on one bike fit on another? Diameter? Splines? If I look around for one, what model year KX125 should I be looking for?

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Postby Bailey28 » 11:26 am May 05 2006

:razz: I knew I would get flamed for the "cleanliness" of my bike.... It has about 20 hours on it so far, no real muddy rides yet. I think the cheap O'Neil boots are wearing more than the paint on the frame! I thought the upc bar code would burn off of the Plat II, but it hasn't yet... maybe I need to ride harder. :mrgreen:


The kicker lever install is still going, I have to add a wee bit of metal to the KDX part to get the lever to rest perpendicular to the bike when its "out" As it is now, the lever passes that point to about 100 degrees. My buddy will weld a small "chunk" that I can machine down to get it perfect. I will post more pics of the machine work I did. Like CC says >>>>Peanut grinder!!<<<<


BTW, check the for sale - wanted ads, I have one extra brand new kick lever, same year KX 125
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Postby canyncarvr » 12:41 pm May 05 2006

Good deal!

Did you use o-rings?

Maybe it's the frame-guard mylar that's wearing out your cheap Oneil boots! :wink:


I used to think a closed top would be a good idea..keep junk out of the assy. I found on my Yamaha (closed top) that it STILL gets junk in it..it's just harder to lubricate.

It'll work great!!

Maybe your bike would get some dirt on it if you rode it other than around the house! :wink:

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Postby IdahoCharley » 08:25 pm May 05 2006

CC - your humor just kills me sometimes - regarding - What is it you would like to see? A studio pic of a short kicker installed on a showroom race bike? ROFLMAO
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