new Lectron Billetron Pro Series fitment on KDX200 / KDX220

[Kevbot]

Are you going to use the malossi 90 on yours?

[Chuck78]

With my Motion Pro throttle assembly, I'll have to use the KX cables + Malossi Dellorto/Bing 90° elbow adjusters, Lectron "stock" 4615-8-L cables (made by Barnett) without an elbow but just a 90° bending arc to the housing, or Motion Pro 01-0772 Lectron etc 42" cables with a 70° elbow built into the cable's carb end, as these will all have the 1" additional length required for the pulley guide type throttles (better than stock KDX throttle).
I have a hunch that the short radius 90° elbow or the tiny 45° radius elbow may work with a stock KDX throttle assembly and stock cable, but it'd be close with all adjusters turned in all the way.

[Chuck78]

I'd say it's advisable for an H-Series KDX Billetron install to run a 90°, 70°, 45°, or perhaps 40° elbow cable guide for the top of the carb, just due to the KDX chassis design with the gas tank in very close proximity.

They shipped my Billetron Pro Series out with no cable adjuster or cable guide (they sell what they call a slip cable adapter @ $13-15 which is just a threaded adjuster for cables like the KDX/KX that don't already have one), but it appears we will definitely need one of the short radiused metal elbows with threads on the carb side and an adjuster on the top side to receive the cable housing termination fitting, as stacking the slip-in/clip-in stock cable into their slip-fit adapter really makes the cable's carb exit far too tall and rigid.
This may necessitate a KX125/KX250 cable from a PWK36/PWK38 carb application if the stock KDX cable doesn't have enough cable length to add the adjuster, & absolutely will require the longer KX125/250/500 2-stroke cables if you want a quick turn aftermarket or KX throttle (recommended!). I have a Motion Pro quick turn throttle from my older Lectron install. Lectron cables for the older carbs are only made for the quick turn throttles with the pulley requiring longer cable length beyond the housing, same as KX throttles.



I have 2 different 90° cable guides that just arrived tonight. The 45° & 40° versions are a lot more common in the USA though, & they may work better due to being more likely to fit the stock cable length. The Sudco 45° cable adjuster guide elbow may be best, but I also see a lot more of the 40° versions. I'd think 40° would be cutting it close to the tank, but perhaps not.

I'll report back soon.

I'll also be reporting back to Matt @ Lectron to make sure he knows of this.


EDIT - to run Kawasaki KX/KDX cables, it appears that an adapter of this sort would be helpful for cable fitment:



EDIT of my edit - those adapters are a 6mm diameter end (0.236" o.d.), but the Lectron slide seems to need a very slightly smaller end around .228" or .230" according to my machinist's drill bit set as inside bore gauges... That are slightly less than 6 mm and am scratching my head as to what actually fits that hole in the Lectron...

The specific Lectron cables by Barnett are intended for the older Lectrons (SAE thread on top cover???), and the new Billetron carbs advertise that they use the stock OEM cables in most applications. From what I'm gathering I believe you're supposed to use your stock slender Keihin PWK 's vertical cable end in the larger horizontal cylindrical hole as the slide is a universal fit for both styles of cable? No slip-on adapter end required???

I also had found YZ owners questioning this same thing on ThumperTalk.
Here's a YZ125 owner's picture from ThumperTalk (test fit, there's a long return spring included thats not pictured):



On a KDX, shortest length 40° or 45° or up to 90° cable adjuster elbow is definitely almost mandatory as the tank sits so close to the carbs. That's how other members had designed cables for the older Lectron carbs in the earlier posts on this topic, custom cable with a 70° or 90° elbow.


Also the 45° Mikuni/Keihin cable adjuster I bought from Niche Supply on eBay was not made well at all, and the Keihin PWK cable end doesn't quite slide through them due to burrs from the manufacturing process (tubing seam on the inside). Bummer. The 90° short elbow will be it...

If I can get my tire change, wheel bearings, and other work done today before 2PM, I might actually get to putting this on today. If not, maybe tomorrow night. Honda buddy coming over this afternoon with all sorts of mechanical problems on two different XR's, needing help...

[Chuck78]

https://www.ebay.com/itm/394000427103

I just ordered an actual Sudco-supplied 40° cable adjuster/guide elbow from Parts Giant on eBay, a reputable business, so that I'm less likely to get cheap Chinese forgeries/clones of the good parts. Sudco part # 007-730. The Niche Supply elbow from eBay which looks almost identical but not quite, ended up being poor quality and not actually fitting a Keihin carb's cable end through the elbow due to casting burrs or more correctly, internal tubing seam irregularities (common on economy-made metal tubing).
If I can clear the underside of the fuel tank on this Sudco elbow, I'll call that the best one for the job, as a 40° bend is going to give less friction than a 45, 70, or 90° bend, and less wear on the metal elbow vs stainless cable. I'll be sure to grease the inside up quite well with molybdenum chassis grease (the black chassis grease for automotive steering and suspension parts as well as the best lube for all suspension linkage and swingarm bearings for our bikes, moly is far better for these applications and for splines than standard bearing greases).

Sudco_007-730.jpg (24.44 KiB) Viewed 26836 times

I believe this should do it, using either a KDX stock cable for stock KDX throttle, or a 1990's KX125-500 throttle cable if using a KX throttle or aftermarket quick turn throttle. My KDX throttle is broken where the cable screws in, and the 220 that I ride full time has a Motion Pro quick turn throttle, but I'll try and compare to make sure the length will work out with an OEM KDX cable and KDX throttle grip. Worst case you abandon your original used cable and throttle and upgrade to a used $25 KX125/250/500 2-stroke throttle (or new aftermarket for $35-$40) and matching new cable for $9-$25.
I found it odd that the Lectron slide had the larger horizontal cable barrel end configuration, but that it didn't match the 6mm (0.236") slip-on brass adapters I have as the hole in the slide was a bit undersized at 0.228" or 0.230". I will probably shave .003" off the brass adapters I have and use them (.006 total diameter reduction via emory cloth hand sanding) just because I'm pretty particular about details, but the cable fits and functions totally fine without that using the stock Keihin cable ends. I found it quite odd that it didn't have a receptacle for the standard Keihin type cables, and I looked up the 2005-2008 KX125/250 2-stroke cables from the Mikuni carb years, and they appeared to have the same carb slide end fitting as the Keihins as well... odd.

[Kevbot]

Keep us updated on what you end up using, I was hoping to reuse my stock KDX cable.

[Chuck78]

The Sudco 40° or 45° cable adjuster/guide hasn't arrived yet, but I put a brand new OEM Kawasaki '95-'06 KDX throttle cable into the Billetron Pro Series with the Malossi 90° cable guide threaded all the way in (with locknut still in place), & pieced together my broken OEM KDX throttle housing, and with the throttle housing end cable adjuster barrel also fully bottomed out into the throttle housing, I have *JUST ENOUGH* cable freeplay!

Screenshot_20230907-083527.png (1.87 MiB) Viewed 26791 times

If I took off the locknut on the Malossi 90° short radius cable adjuster and bottomed the adjuster fully, I'd probably get enough freeplay to back out the throttle grip adjuster, which would be perfect. Although I didn't check this to see if the threads bottom out in the 90° elbow before that happens, that threaded adjuster end could be shortened up on a grinder and deburred if that were the case. Hopefully the Sudco 40° elbow adjuster comes in today or tomorrow and I can check to see if it has just a touch shorter length to it (I'm fairly certain it does).
Also note that new cables tend to stretch after a bit of use, so this might help as well with a bit wider margin.


So I got a 1990's KX OEM Kaw cable (about 4mm additional cable stick-out vs the 2000's KX Motion Pro cable), and an early 2000's KX Motion Pro cable, and the housing length overall was well over 2 inches shorter than the KDX cable on both KX's, but the cable stick out was 1 inch longer (the crucial part), which was designed to accommodate a PWK36 or PWK38 + the slightly longer requirements of a nicer throttle assembly with a pulley instead of just the curved guide on the KDX cable. The KDX's stock cable housing is quite long, longer than needed even with bar risers, but the KX is fairly short on housing length. Since I have Motion Pro quick turn throttles for both bikes now, I'll be trying the KX cables or else maybe selling those and getting throttles that are more designed like the KDX although maybe with a smaller pulley.
I also may try a Honda CR or Yamaha YZ cable to see if the length overall is any better (closer to 41.5 inches long housing length end to end, KDX is over 42").

[Chuck78]

Well... I got the Sudco 40° elbow adjuster today, which looks nearly identical to the Niche Supply 40° cable adjuster elbow, but is of SUBSTANTIALLY higher quality immediately noticeable, and the inside diameter of the tubing is full diameter with no tubing seams or burrs that need reamed out on the ends. The Keihin cable actually fits through!!!

IMG_20230907_211029~2.jpg (1.53 MiB) Viewed 26777 times

Well, then I made an unfortunate discovery... The OEM Kawasaki KX and KDX cables have a clip-in style interface into the top cap of the Keihin carburetors. I only tried the shorter of the cable guide adapter elbows, and since the Niche Supply 40° Keihin elbow wouldn't even fit a Keihin cable due to poor manufacturing quality, I only tried the Malossi short 90°... Which does in fact just barely work as far as stock KDX cable length with stock KDX throttle thankfully!

BUT... the other three that I bought don't work at all!

Screenshot_20230907-215900.png (1.96 MiB) Viewed 26777 times

It's a simple modification, just drill out the end of the adjuster barrel on the Sudco 40° elbow guide slightly larger to fit, but I was really trying to find the simplest most straightforward bolt-on & off-the-shelf way to fit these so that everyone can easily do this upgrade... And was hoping to use OEM Kawasaki cables, KDX or worst case KX... Still easily doable, KDX cable + Malossi 90° cable adjuster elbow minus the lock nut & barrel bottomed out just makes it as far as cable stick-out length versus cable housing length, or perhaps the Sudco 40° elbow with end drilled out to fit, although with the long crimped on steel end on the Kawasaki cable housing, this still puts it tight to the tank...





SO..... THEN ON TO THE REAL BREAKTHROUGH....
to be continued...

[Chuck78]

Well... I could've spent a little bit more time looking around at various options... I was wondering out of the 6 or so different Motion Pro aftermarket throttles as well as Domino throttles, Gunnar Gassers, Whirlpulls, etc... Some of these have to use a slightly shorter cable length, right? Well I think most of them are fairly standard, most of the nicer throttles with the brass bearing pulley system to eliminate wear and tear from the cable sliding through a radius that is rotated 90° from the direction the cable was just bending around the throttle tube....

.


BUT...

r5w38ndo7fe9uqv3seao8yiu4l3d.jpeg (63.75 KiB) Viewed 26776 times

I happened to see that Motion Pro had Universal and Custom cable links in their menu... I was pleased browsing these universal cables' links for photos,
but then I came upon the chart that specifically showed 3 different length cables for Keihin, Mikuni, and LECTRON carbs!
AND.... The cable already has a 65° or 70° elbow on the carb end!!! AND FOR $19.99 RETAIL PRICE!!! smh...

Screenshot_20230907-212347~2.png (119.81 KiB) Viewed 26776 times

It's recommended to use their Turbo throttle with it (the extra cable length is specifically made to run the nicer pulley style throttles), although an OEM used KX 2-stroke throttle would also work I believe. Their throttles are VERY affordable, FYI, with the Turbo throttle retailing at $29.99... basically a remake of Gunnar Gasser & Whirpull throttles.

Screenshot_20230907-182936.png (435.55 KiB) Viewed 26776 times

I'll investigate if I have time but the standard Lectron cables made by Barnett should likely also work with this Malossi or Sudco elbow, as the diameter should be correct to slide right into the Sudco Keihin/Mikuni 40° elbow... The Motion Pro 01-0227 cable already has the elbow built in though!

[Chuck78]

Now I'm really banging my head against the wall, again! I've been test fitting everything with a brand new 54012-1485 Kawasaki KDX OEM cable that I've been keeping in my crate of spares / premix oil / etc that I always take to the trails with me.

Screenshot_20230907-224846.png (1.87 MiB) Viewed 26772 times

I then go and look at the OEM appearing cable on my stock 220, to see how well it makes the bend from the top of the PWK33....

WHAT THE $#@&!?!

IMG_20230907_224200.jpg (4.14 MiB) Viewed 26772 times

There's a metal elbow on the thing!?! How'd I miss this?!?! I'm not sure if this is even OEM...???

I'll just go right out and blame too many late nights and too much to do... on both accounts, of missing this variation of the stock cable with a steel elbow, and also not noticing the Lectron Universal cable fitment on the Motion Pro site...

No clue what the origins of the currently installed elbow-end OEM-appearing cable are, I've tried searching eBay and the OEM Kawasaki parts fiches.... Zero clues anywhere...



So here it is, stock cable Kawasaki # 54012-1485 straight end + stock KDX throttle + Malossi short radius 90° cable adjuster elbow,
https://www.lucky2strokes.com/90-Degree ... ndy_90.htm


-or-

Motion Pro Universal Lectron cable
+ Motion Pro Turbo throttle (Gunnar Gasser / Whirpull reproduction)
-or- the fancier revision the Motion Pro Turbo SE throttle for double the price...

https://www.motionpro.com/product/01-0227
+
https://www.motionpro.com/product/01-0057
-or- $$
https://www.motionpro.com/product/01-2813


And don't forget that the Billetron carbs fit an H-Series KDX a lot better WITH the Moto Tassinari VForce3 or VForce4 reed cage assemblies or Boyesen RAD Valve intake/reed blocks! Big upgrades over stock... Boyesen wins it for me over quality construction (machined from a solid chunk of billet aluminum) although the VForce3/4 may perform marginally better, but are made from plastic... Most love 'em but others say especially in mountain riding where you may see drastic temperature changes and do hot engine taxing slow climbs up to high elevations where temps get quite cold, they have been known to crack from the drastic temperature swings and hot engines getting shocked with cold mountain air... My VForce3 has dine great for 3 years of 700ft - 5,000ft elevations though!

[Kevbot]

Thanks for the update chuck, I did get my billetron in the reed and intake boot today, seems to fit nicely. It does sit a little cockeyed but not to bad. I heard from someone else that their billetron for the KDX shipped with a 90* elbow so I reached out to Lectron to see if they will send me one for free. otherwise I might just spend the $50 and get a new cable and throttle from Motion pro.

For tank petcock I did get the lower one that you recommended, should work but it might get close to interfering with the throttle cable.

[Chuck78]

Kevbot, I've got the Motion Pro Universal Lectron cable supposedly arriving Wednesday-Thursday. I'll let you know how it'll work out.
I couldn't find any photos other than generic stock photos of other cables, or the official stock photo for this exact cable (with part# in photo), which was not clear enough of a photo to even tell if there were threads on the end of that elbow. It might require having an adjuster already in the carb (if no threads), which I would still need the Lectron slip fit cable adjuster then... And which would also make it a taller install height...

I'll get this figured out sooner or later!

It's a bit frustrating, I would have liked to have had this on my bike 6 weeks ago, but I'll take one for the team to get this figured out for beat easiest fitment onto our bikes

I might just run the universal Lectron lectron long version cable manufactured by Barnett, which has a permanently installed threaded adjuster on the end that screws right into the carb top, so I cannot remove it to install anything else unless I were to cut it off with a Dremel tool. I may just run that for the time being but it will put a tight curve in the cable there. This may be acceptable, as the stock replacement OEM KDX cable also will have to make a 90° bend to hug the underside of the tank, patron is just a bit taller though also slightly tighter bend. I wish I knew what the origin of this cable that is on the bike with the 90° elbow would be, but the OEM replacements are not like that at present. Either this was aftermarket or Kawasaki manufactured them differently in 1999 versus what they currently sell. That cable had one strand frayed up at the throttle grip area unfortunately... So it's time is limited, and I'm trying to find an off-the-shelf available easy solution here.

[Kevbot]

I noticed that Lectron has the 90* listed on the site now under configuration but no under regular products:
1 x 90° Slip in Cable Adapter ('95-'07 KX125 & KX250) + $15.00

But its $15 and another $15 to ship so I might as well get the motion pro stuff...

[Kevbot]

Well Lectron got back to me and wants $32 to ship their 90* adapter! You think the Sudco 45 will work, going to pop my tank back on over lunch and check the clearance.

[Chuck78]

The Malossi 90° or other Bing/Dellorto carb M6-.75 thread 90° or 70° elbow is what you'll want for stock cable + stock throttle housing, or KX cables + pulley type quick turn throttles. That should work out perfectly.
May need to remove the lock nut on the short Malossi 90° adjuster elbow in order to bottom out the adjuster further to get a slight nit more freeplay in the cable to avoid unwanted throttle when turning bars to full steering lock.
One of the KX cables and a longer Bing/Dellorto carb 70° or 90° cable adjuster elbow may also work with the stock throttle to give more freeplay.
I have the Motion Pro Universal Lectron 43" cable arriving today, hoping it has threads on the end! May require a straight adjuster otherwise...

I'm departing for a big riding trip shortly, still on the old Lectron carb, but once I'm back, I'll review these cable options and if not fully happy with the Lectron/Barnett off the shelf cable with no elbow, I'll have Barnett design a 42" housing length cable with a teflon lined M6-.75 elbow and mid adjuster with proper ends for the Billetron and KX/aftermarket throttle. With the mid adjuster, one cable could probably suffice for stock throttle AND pulley type motocross/aftermarket throttle perhaps.

[Chuck78]

Basically the Malossi 90° short elbow for Bing/Dellorto carbs should allow stock cable + stock throttle,
& same Malossi 90° Bing/Dellorto adapter + 1990's KX cable & KX or aftermarket pulley type throttle should also sufficiently work, although with tall bars and risers, the KX cables may be a bit on the short side. I will test this fitment soon.

Lectron 4615-8-L universal cables should work but will bend a tighter 90° curve on underside of tank.
*IDEALLY* a non-existent Lectron part # of 4615-8-90-L would be the cable needed for KX & KDX & many bikes, but they don't offer this. Just the standard 4615-8-L but with a teflon-sleeved 90° or 70° low profile M6-.75 threaded adapter directly out of the carb instead of the straight M6 adapter on the 4615-8 & 4615-8-L cables.

The Motion Pro Universal Lectron/Keihin/Mikuni 42" cable arrived, no threads on either end - throttle would need slotted adjuster barrel to slip over this, and carb would need a straight M6 threaded adapter to receive the non-threaded 70° elbow, increasing the stack height - may or may not clear without rubbing the gas tank's underside.

I'll try this upon my return from an epic Redbird Crest Kentucky gnarly trail riding trip. Billet clutch basket + Rekluse in her 200 XC-W + new radiators, & my KDX 220 is apart for tires, wheel bearings, coolant flange gasket replacement, & more... Prepping for some of the best (& most seldom traveled) rugged enduro trails in the Eastern USA, round 2! Sad that it looks like we'll only get 2 extended weekend Redbird Crest trips in this year... AMAZING riding area!

[jedidan45]

Excellent thread so far - THANK YOU for your continued diligence and hard work!!!

[Kevbot]

Got the 90* from Lectron, going to install tomorrow. Ill try and snap some photos as well as get some video of the install/running.

[Kevbot]

Here is the 90* from lectron with the stock KDX cable pretty much all the way out.

[Chuck78]

What about your throttle tube side adjuster?
That's odd as it looks to be a different amount of cable than what I've got on my new OEM KDX cable

Screenshot_20230921-112257~2.png (1.32 MiB) Viewed 26628 times

Video with brand new OEM KDX H-series cable and stock KDX throttle:
https://photos.app.goo.gl/2RXs3EBZekBGdEVY9

Kevbot, I could ship you a KX cable if all else fails, as long as you don't have terribly tall bars or risers.

[Kevbot]

I did bottom the cable out, I think think the 90* from lectron is longer than the one you are using because its close for the slide to bottom out.

Also the stock petcock seems to interfere with the choke, I have the yamaha one to replace it so will try that.