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I played around with ti some more and cut the threads on the 90* adjusted to get it shorter to get some more cable length but still can't get it to bottom out. I might have to look at the KX or another cable. I am using 1/2" risers and CR fat bars (not cut)

The standard Lectron cable offering should work for you I'm betting, it works for the older Lectron carb but could use a 90° elbow also, but should work great with a Motion Pro Turbo throttle or other aftermarket pulley type throttle. The pulley adds a bit of length but gives the cable an easier life due to less friction.

Sorry you had to buy the Lectron elbow to find it was too long.
I do have an extra Motion Pro KX cable that may work for you if you can wait for me to mail it.
That or the Malossi short radius 90° elbow should be what you need.

Lectron actually sent the elbow free of charge otherwise I would've gotten the same as yours. How much do you want for the KX cable, I would buy it from you vs ebay or motion pro directly?

Ended up buying a motion pro KX cable for $12, once it gets here I will get it installed.

I didn't like how the 90 elbow came off the carb and mated with the throttle cable. I thought I would heat up the 90 and bend it to a less aggressive angle, when I went to bend it, it snapped right at the 90.

I went ahead and ordered the Sudco 40* https://www.ebay.com/itm/394000427103 which comes of the carb at a way better angle to the throttle cable, and I am back to using the stock KDX cable!

I will try and snap some photos tonight.

Was able to get out yesterday afternoon and test the new top end and carb, it was a whole lot of fun! I still need to do some tuning on the lectron as it seems to not like just cruising throttle at 1/4-1/3 twist.

One side of the carb does seem pretty full since it sits at a slight angle.

Idle/first start no adjustments: https://www.youtube.com/shorts/2q6PhDy5Y9g

Kevbot wrote: ↑09:41 am Oct 16 2023 Was able to get out yesterday afternoon and test the new top end and carb, it was a whole lot of fun! I still need to do some tuning on the lectron as it seems to not like just cruising throttle at 1/4-1/3 twist.

One side of the carb does seem pretty full since it sits at a slight angle.

Idle/first start no adjustments: https://www.youtube.com/shorts/2q6PhDy5Y9g

Hey Kevbot, thanks for the pics and video...any chance you have a pic of the top of the carb where the elbow and tank area are?

I got my Billetron Pro 38 installed the other day on my '98 220 with the vforce reeds.
Fitment is near perfect; tight but it fits.
Used stock throttle and throttle cable, everything backed off to the max.

Alright! We're getting some more Billetron Pro Series KDX users now!

jedidan45 wrote: ↑10:26 am Nov 28 2023

Kevbot wrote: ↑09:41 am Oct 16 2023 Was able to get out yesterday afternoon and test the new top end and carb, it was a whole lot of fun! I still need to do some tuning on the lectron as it seems to not like just cruising throttle at 1/4-1/3 twist.

One side of the carb does seem pretty full since it sits at a slight angle.

Idle/first start no adjustments: https://www.youtube.com/shorts/2q6PhDy5Y9g

Hey Kevbot, thanks for the pics and video...any chance you have a pic of the top of the carb where the elbow and tank area are?

Yeah I will grab some pics, getting the itch to ride with this nice weather we have been having. Need to finish up a couple things and get the carb tuned a little better. I have a dead spot on the low end power, idles great and up top it screams. Also ordered a boyseen rad valve since my boot might be leaking a bit with the Vforce 3.

Chuck78 wrote: ↑11:05 pm Nov 30 2023 Alright! We're getting some more Billetron Pro Series KDX users now!

Hi everyone! Add me to the list of Pro Series KDX users for my 2005 KDX 220. Hunter at Lectron support pointed me to this topic because I was running into some issues with the throttle cable. I ended up replacing the stock with a replacement and used the 90 degree bend supplied by Lectron.

I had a heck of a time getting the Lectron to fit "nicely" - as in getting the airboot to slide over the large part of the Lectron and then being able to get the smaller side in towards the motor was tricky....all while keeping the top angled just right to not hit the frame :-)


My next issue was the looooong stock petcock/fuel tap pushing up against the choke. I ordered the one linked here from partzilla and hope that sorts me out.

I mostly wanted to say thanks to those of you who've contributed to this topic - it's been very informative!

If you have a Boyesen RAD Valve, those should fit an unmodified Billetron a lot better than the stock intake with a VForce3 or VForce4 reed block. The airbox bell long body adapter I had Lectron machine down almost to the dimension of the PWK 35, but there's not enough material to go all the way down as I mentioned before. It fits fine when reduced to within a millimeter or two of stock diameter. It's not that much bigger anyways, but I didn't want to stretch out the air box boot too much. The RAD Valve coupler is an easy piece to replace or even source an alternate silicone coupling for, so that's less concerning.

The cable elbow that Lectron supplies still isn't really what's best. That custom order Barnett cable based on the drawing with the part number "Todd Miller" is really what Lectron should be selling for a multitude of bikes, not just 95 and up KDX. My stock universal Lectron cable broke right where it makes the sharp bend between the carb and the gas tank. It's also a high quality Barnett cable, but the only flaw is that it didn't have a 90° or 70° elbow with a Teflon liner sleeve in it.

Has anyone tried the Xcelerator metering rod for the Billetrons yet?

I'll be looking to get one of those this summer when I get back from a long road trip this month. That's really going to be the absolute ultimate carburetor setup for a KDX...
They weren't available yet last summer when I was working with Matt from Lectron to test fit the Billetrons to the 95 and up KDX, but now you can get them as an add-on option when you buy the Billetron new.

mthendri wrote: ↑11:41 am May 03 2024

Chuck78 wrote: ↑11:05 pm Nov 30 2023 Alright! We're getting some more Billetron Pro Series KDX users now!

Hi everyone! Add me to the list of Pro Series KDX users for my 2005 KDX 220. Hunter at Lectron support pointed me to this topic because I was running into some issues with the throttle cable. I ended up replacing the stock with a replacement and used the 90 degree bend supplied by Lectron.

I had a heck of a time getting the Lectron to fit "nicely" - as in getting the airboot to slide over the large part of the Lectron and then being able to get the smaller side in towards the motor was tricky....all while keeping the top angled just right to not hit the frame :-)


My next issue was the looooong stock petcock/fuel tap pushing up against the choke. I ordered the one linked here from partzilla and hope that sorts me out.

I mostly wanted to say thanks to those of you who've contributed to this topic - it's been very informative!

I have a 2004 KDX220 with Boyesen Reeds and am considering the Billetron Pro. To clarify, did you have an OEM cable and you just ordered a new one to freshen things up before installing the 90 degree adapter?

I am planning on running the OEM cable with the supplied 90 degree adapter but want to make sure this is the optimal setup before I place my order.

I ordered a new cable because the one that was on there (which I think was OEM) had a threaded end where it connected to the original 90 degree adapter on top of the twist of throttle cap. The 90 that Lectron sent wasn't setup with an end to thread into that throttle cable..... And, also to freshen it up.

Chuck78 wrote: ↑05:49 pm May 03 2024 If you have a Boyesen RAD Valve, those should fit an unmodified Billetron a lot better than the stock intake with a VForce3 or VForce4 reed block. The airbox bell long body adapter I had Lectron machine down almost to the dimension of the PWK 35, but there's not enough material to go all the way down as I mentioned before. It fits fine when reduced to within a millimeter or two of stock diameter. It's not that much bigger anyways, but I didn't want to stretch out the air box boot too much. The RAD Valve coupler is an easy piece to replace or even source an alternate silicone coupling for, so that's less concerning.

No RAD Valve or VForce - so that may be part of my issue.

mthendri wrote: ↑07:47 pm May 07 2024

Chuck78 wrote: ↑05:49 pm May 03 2024 If you have a Boyesen RAD Valve, those should fit an unmodified Billetron a lot better than the stock intake with a VForce3 or VForce4 reed block. The airbox bell long body adapter I had Lectron machine down almost to the dimension of the PWK 35, but there's not enough material to go all the way down as I mentioned before. It fits fine when reduced to within a millimeter or two of stock diameter. It's not that much bigger anyways, but I didn't want to stretch out the air box boot too much. The RAD Valve coupler is an easy piece to replace or even source an alternate silicone coupling for, so that's less concerning.

No RAD Valve or VForce - so that may be part of my issue.

Absolutely. I tested it both ways for Lectron thanks to Matt Denecke sending me a scrap bin Billetron, it fits substantially better WITH the Boyesen RAD Valve. If you pay Lectron extra $$ to turn down the intake spigot side 2mm(?) diameter to match the PWK33/35 spigot diameter, you can also run the VForce3/VForce4 reed cage and stock intake, but the stock intake doesn't stretch so nicely like the Boyesen RAD Valve intake coupler does if you're running the PWK36-38 spigot diameter that's stock on the Billetron.

The RAD Valve pushes the carb back further, and being angled to the left rear, that means it moves it further away from the headstay engine mount (the portion welded to the frame).

I have an OEM cable that I've had new in the package as a spare for quite some time and this is what I tested mine on, although I won't be running that as I want an aftermarket throttle anyways. They are slightly quicker turn and much smoother as they have a pulley on a bearing instead of an arcing cable guide path.

The OEM cable and the Malossi brand 90° elbow with all adjusters completely bottomed out was just barely enough on a brand new non-stretched cable to give me a very slight bit of free play enough to call it acceptable. One person was complaining that they could not get free play out of this setup. Another said Lectron provided elbow was a bit too long I believe. I tested this setup for Lectron, but they never sent me one of their threaded 90° elbows, I sourced those on my own to figure out what would work without hassling them about sending me more free stuff.

Ultimately, the custom order Barnett cable will be the absolute best thing as it has a Teflon sleeve lined 70° elbow built into the cable, and their cables are top quality. I snapped the standard Lectron cable with 8 mm thread for KX etc throttles, and it snapped right above the carburetor where it makes the 90° bend below the gas tank to run horizontal up front. I think the custom Barnett cable will last significantly longer and pull smoother. The standard Lectron cable lasted me three seasons of heavy use. Not enough by my standards.

I should note that I believe Barnett makes the Lectron standard universal cables as well, and they should offer one with the 70° or 90° elbows built into them, as this would make them last longer, but this is what electron provides. That's why I went with the custom order $64 Barnett cable. I'm not a broke 20-something kid anymore, and I love my KDX220's tremendously, so I'm not afraid to pour money into it. It's still cheaper than buying a new bike to abuse and destroy in a few seasons and rebuild & repeat.

The KX OEM cables correct amount of extra cable versus housing length to run the aftermarket throttles, unlike the stock KDX cable.

One of the Motion Pro universal cables that has a 90 elbow on the end of it actually might still work, but it doesn't have a threaded end on the metal 90-ish degree elbow. You can get a straight threaded M6 cable adapter for the Lectron carb (also fits Mikuni/Keihin and others), but this might put the metal adapter pretty close to the bottom of the fuel tank. I actually bought a thread die in that M6 fine thread pitch size with the intent of seeing if I could thread the end of the non-threaded motion probe universal cable elbow.