1990 KDX200 Kick Start Boss & Lever Compatibility

Discussion specific to the 1989 - 1994 (E Series) KDX200 model sold in the USA
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gfalcone1
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1990 KDX200 Kick Start Boss & Lever Compatibility

Post by gfalcone1 » 01:37 pm Oct 02 2020

I know there have been some posts on this topic, but I haven't seen the end result anyone had or problems they discovered. For example:
viewtopic.php?f=77&t=18858&p=170254&hil ... rt#p170254

I lost my boss and kick start lever assembly somewhere last week, and now I have 2 questions. The kick start shaft itself looks to be in great shape.

Q1: does anything go on the shaft (i.e. a washer) before the boss? What about after the boss, before the hex nut?

Q2: What boss/lever combo will work on the 1990 that might be made for another bike? Any Ebay parts that would work out or is that all crap (or this


The parts shop quoted me $157 and I would rather not spend that much of course.

Thanks!

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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by KDXGarage » 08:40 am Oct 03 2020

Here is the 1990 diagram. If available, a used one off eBay or elsewhere might prove stronger than an Amazon one.

Image
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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by doakley » 11:15 am Oct 03 2020

Would this be a good time to make the switch to the KX125 kicker, if applicable to his model?

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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by Bmarc » 11:39 am Oct 03 2020

Honest question: What benefit would it be to modify the kicker? I also have a 90 and mine is wallowed out. It still works but what would the advantage be of using a kx 125 kick start over the oem 200?

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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by KDXGarage » 01:35 pm Oct 05 2020

I think someone once commented that getting stuck in a rut or on a hill was helped by a shorter lever.

Weight would be another benefit.

I don't know if the 1989 - 1994 have the KX option. I can't remember.
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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by Molly's 70 » 03:48 pm Oct 05 2020

I did the swap on my 03' 220. I like the shorter kick.
If you lend someone $20, and never see that person again, it was probably worth it.

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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by gfalcone1 » 06:45 pm Oct 05 2020

Molly's 70 wrote:
03:48 pm Oct 05 2020
I did the swap on my 03' 220. I like the shorter kick.
Which model and year did you use?

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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by Molly's 70 » 03:14 pm Oct 11 2020

I don't remember. I read about it somewhere online. Maybe fredette's site.
If you lend someone $20, and never see that person again, it was probably worth it.

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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by doakley » 04:50 pm Oct 11 2020

Search these forums. I’m pretty sure I found the info here.
Advantages are the kicker is a much more durable design and doesn’t get that flop out angle of the stick KDX kicker. It snaps back in place better which is good for hare scramble starts.
The KDX is easy to crank and I find the shorter throw means I don’t have to pick my foot up as high. That helps in tight places like deep ruts or hill sides.

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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by Molly's 70 » 05:22 pm Oct 11 2020

If you lend someone $20, and never see that person again, it was probably worth it.

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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by KDXGarage » 05:49 pm Oct 11 2020

Hey, now. All you rich folk running around on them there 1995+. 1989 - 1994 KDX200 kickstarter does not suck as bad as 1995+. :drinkers: :busted: :pop:
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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by Guffer » 09:14 am Nov 14 2020

Just installed the shorty FRP kickstarter on my 89 and it's a huge improvement. I'm 6'2" and getting my foot up that high on the oem kicker in tight situations was the biggest reason for switching. The FRP kicker is expensive, but seems worth it based on build quality. The boss was still in good shape but ended up replacing all the small parts (o-rings, washer, circlip, ball, spring, set screw) since they were original items. Fredette has all those parts available including the boss should you need them.
1989 kdx200

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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by KDXGarage » 12:42 am Nov 15 2020

Thank you for the report.

PLEASE!! Loctite the nut onto the shaft.
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Re: 1990 KDX200 Kick Start Boss & Lever Compatibility

Post by Guffer » 10:01 am Nov 15 2020

That and torqued to 36 ft-lbs. Blue thread locker is my most used tool.
1989 kdx200

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