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Here's what's left of the lever. Also I'd love to replace the clutch one while I'm at it.

That's crazy!

Look to see if the KDX lever part number is the same as a KX lever. If so, then shop for the KX lever, as some lever companies might not list it as fitting a KDX. The part number is in a 12345-6789 format.

That would certainly mimic a spongy brake, as the pressure got higher the lever was likely flexing inside the copper sleeve and making it feel soft.

As for levers, the OEM ones are available (at least here in the states) for relatively cheap. Any KDX 95-07, KLX300 same years, KX125/250/500 93-96. Aftermarket ones are available but most are the normal length. ASV makes some nice stubby ones, but they aren't cheap.

The repair was quite rigid, but did not respect the proper shape of the lever!

I found nice UFO and ProTaper leversbut too expensive (80 to 100 €). There's a lot of more or less OEM shaped stuff, with quite low prices but sometimes they feel like AliExpress crap.. I finally found a medium priced one that is foldable and has a warranty. They also make the clutch one.

https://www.24mx.fr/pieces-pour-motocro ... PM-0013824

I quickly installed on the bike and the available travel is much, much longer! At least twice as long. Lever is firm and won't touch the handle unless applying exessive strenght.
I need to adjust it now and bleed it properly. Right now it already feels good, much better than before, but I'm pretty sure it's not fully bled.


Can't wait to finish the job and give it a try!!

Wow. What a long journey. I hope it all turns out well.

I think it's finally over!

Took some quiet time tonight to bleed it, and set the lever action.Lever is nice and firm. I had to get rid of my barkbusters,the lever was touching them and I didn't want to cut it so I put some flag-style handguards instead. Last detail would be to add handlebar plugs.

Thanks to everybody for the help, the issue was right in front of my face the whole time..


Tomorrow I've got a ride planned we'll see how much it improved the bike.

Good! Report back with the god news.

Solved!

Had a nice 3 hour ride this afternoon, the brake is good, one finger action.
Next step would be to replace the disc and pads with better ones to get the maximum power and feel but right now it's really nice!

All of this because of a badly repaired lever..

Excellent!

Thanks for the follow up. I am glad you got it all sorted out.

Wow!! Congratulations.
When I broke mine, I replaced w the $12 OEM style from Outlaw racing and it has worked fine. But I do like the one you picked much better so will put that on my list for next time.
So glad this is finally done. That must feel a huge relief.

Darn, Guess not. Oh well, maybe next trip to Toulouse!

Too bad,

UFO makes a really nice one, more expensive though.

I falled a few times during the last ride and the foldable lever stood up well, it's worth it if you do hard stuff