KX250F Kickstarter on H-Series?

Discussion specific to the 1995 - 2006 KDX200 (H Series) and 1995 - 2005 KDX220R (A Series) models sold in the USA
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bufftester
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Re: KX250F Kickstarter on H-Series?

Post by bufftester »

What about taking a torch to the first bend where your foot goes and just flattening a bit of that angle out? Seems you wouldn't need to do much to get there. I'm interested to try this on my Hybrid, but luckily my OEM kicker is still in very good condition.
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Re: KX250F Kickstarter on H-Series?

Post by SS109 »

@John_S Hmm, I think a small plate bolted on between the upper pipe mount bolt and the mount would keep the kicker from hitting the tank even in a crash. That's what I will try when I make the swap. Could make the plate even go all the way to the head stay and bolt on there as well if you want it really strong. I also might try spinning something up on the lathe for the spacer behind the kicker.

Thanks for the awesome pics and insight! :supz:
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Re: KX250F Kickstarter on H-Series?

Post by Tyl3r »

John, you might be able to get away with just cutting off the nub at the end and it wont hit the tank. Trying to straighten it out some might be the trick too tho...im nervous Id mess it up!

I have some metal shim washers i ordered off of mcmaster carr to use as spacers. I think im using 2 behind mine, they are probably in the ballpark of 2-3mm thick, i cant remeber off hand.
Shoot me a PM and i can mail you a few of them. I had to buy a whole pack lol
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Re: KX250F Kickstarter on H-Series?

Post by John_S »

Good suggestions you guys. I have a plan that I think will be fairly easy looking at it again today. When you open and close the boss looking at the lever upside down (off the bike) it shows you exactly how much to relieve and not affect the function at all. I'll get the piece all cleaned up, make some marks on it and take a couple pics.
Thank you Tyler for offering up the spacers. That would be great. I was thinking I was going to have to buy a 5/8 id 7/8 od metal spacer sleeve and then cut it down. I'll send you a pm.
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Re: KX250F Kickstarter on H-Series?

Post by John_S »

Update…it’s going to work without much hassle. Tyler is sending me some 22 OD x 16 ID x 1.5 thick stainless spacers. 2 of those will space it out just right.

The only tool I needed to modify it is a grinder with a 4 1/2 metal cut off blade. Knowing what I know now and if I had the washers on hand, I could take a 250F lever, shave a little here and there and have it mounted in 10 minutes.

I cut the lever down one ridge like I had it marked on a previous post and also shaved down the long ridge that faces the ceiling. Even cut down it’s the same size as the stock lever where you place your foot. It clears the gas tank and snaps shut with a positive click.
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Re: KX250F Kickstarter on H-Series?

Post by John_S »

See where I put a pencil mark on the right side of the lever that follows the line of the boss? That’s where you have to relieve it for it to clear the clutch cover. Once you do that and make the little “slice” on top of the lever to clear the frame, the fat part of the lever hits on the back of the foot peg just like it should.
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I should get the spacers next week sometime. I’ll clean up my grinds a little before then and it should go on without any issues and be a nice alternative to the stock lever. I’m excited about it now.
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Re: KX250F Kickstarter on H-Series?

Post by SS109 »

This is awesome. My KDX will for sure be getting this mod down the road. Maybe when I do my AF conversion.
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Re: KX250F Kickstarter on H-Series?

Post by MoonStomper »

It looks pro, nice work Sir!
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Re: KX250F Kickstarter on H-Series?

Post by John_S »

Thank you moonstomper. I got the stainless spacer tonight that Tyler sent me. I thought I would need 2 but 1 is just right and has the shaft just barely proud of the nut.

Long story short… one 22x16x1.5 spacer, cut some length off where your boot goes, shave the part down that would come in contact with the clutch cover, and I shaved about 1/16” from the upper left where the socket rides to tighten the nut down so the socket doesn’t get wedged in there.

It’s bolted up and got it’s first start tonight. I think it’s a great modification and worth the effort. Mine is used but RMATV has OEM ones in stock for $104.
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Re: KX250F Kickstarter on H-Series?

Post by Tyl3r »

I agree, its a good mod, worth the effort. I found a flapper wheel on my grinder worked very nicely to remove the necessary material from the kicker and the boss (I took a little off of there too). Other than that, about the same mods that John mentioned for me as well, but I think I have two washers behind mine.
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Re: KX250F Kickstarter on H-Series?

Post by SS109 »

This is such a simple yet awesome upgrade IMO. I'm looking forward to doing it to mine.
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