KDXRIDER.NET

I'm having an issue replacing my front brake lever on my 2005 KDX220.

Kawi dealer and all the fiche I can find on the net show one style of lever yet my bike has another.

Any thoughts?

That master cylinder looks stock, but the push rod does not. You should be able to go back to a stock lever, and modify that rod to work. That rod just pulls out of the rubber boot.

gregp wrote:That master cylinder looks stock, but the push rod does not. You should be able to go back to a stock lever, and modify that rod to work. That rod just pulls out of the rubber boot.

I've tried to pull that rod out and it won't go. I'm afraid to pull to hard as to damage things.

I too think master cylinder is stock, as the former owner was not the type that would replace such things and she was the orininal owner. When I bought the bike it had the "greenie handgaurds" in place and looked very stock.

Should I just yank on that rod?

slow down there buster, u can't yank it out just like that. The is a circlip behind the rubber piece holding the rod, just pry it out slowly so you don't damage the rubber. you''ll see the circlip inside holding the rod to the master cylinder. Looks like the po didn't bleed his break properly and add spongy feel and tried to solve the issue that way.

So remove the circlip. Take out rod. Does this look right?

yup think so. you'll have to refill your master cylinder and maybe bleed the brakes though.

Sorry, I didn't mean to misguide you. I do not recall my setup looking like that...

Mine dose not look like that ether.

That setup with the attached rod looks like the one on my 99 KX500, but does not look like the setup on my KDX 220s.

yes, just remove the circlip with a circlip piler and then you can pull out the rod. you might want to pour out the brake fuild in the master cylinder first as not to creat a mess. i suggest you change the whole internal pump with a new want and then you could run the oem or aftermarket lever. beeld the whole system with dot 4 fuild. good time also to clean everything up.

I found a lever that fits perfectly. The package says it goes to a whole bunch of late 90's KX's. Problem solved.


I also spoke with the former owner and she swears up and down that the brake lever/master cylinder were never replaced since new.

Whatever... I'm just glad I found one that fits!

Thanks to all for the help! Happy New Year!

That is indeed a strange set-up. Gotta be some kind of PO add on going on there.
Here's what a stock '04 master cylinder/lever looks like..

This is what I got... good, bad, or indifferent. 2003 KX500 set up.