Broken clutch compression release..am I screwed?

[DenverKdxRider]

I've got a 96' KDX 200 and before the season starts...I decided to put on some new clutch plates. As I was trying to put on the case..I some how managed to break the clutch compression release. . I thought..shoot welp..I'll just go order another one but..it's "No longer available". The part number is: 13236-1264. I've searched on ebay for a used one..but can't find a used one.

What are my options to get this fixed? I thought JB weld..but I have no confidence it'll hold up. Also taking it to a welder. Is there a similar lever that might fit from a KLX?

[Molly's 70]

If you use JB Weld, and it doesn't work, just remember that it really messes with the welding process. I would have it TIG welded if you can.

[DenverKdxRider]

I ordered a 2001 KLX 250 compression release lever. It looks almost identical. Fingers crossed it fits!

[SS109]

JB Weld absolutely won't work on that. Best place to find one is on Ebay or on the forum here. Certain year KX125 actuators will work as well. Please let us know if the KLX250 actuator works but I got a strong feeling it won't.

[DenverKdxRider]

I tried to use a 1994 KLX 300 actuator and you were correct. It doesn't fit. What's worse..I gave the broken actuator to get welded by a local business and he completely broke it. He offered me compensation but I am still in the same spot..is there a particular year for a KX125 actuator that I should be looking for?

[SS109]

According to John_S's thread (viewtopic.php?f=77&t=23324&p=214337&hil ... ll#p214337) he used one from a '93 KX125 so that means a '92 should work as well.

Sadly, I just checked Ebay and the actuator, a cover with the actuator, or an inner side cover w/clutch cover and actuator are all non-existent currently for the KDX or KX125.

[DonnyV]

Have you checked Kawasaki parts house, it shows will ship 1 to 4 business days, maybe it's different if you put it in the shopping cart, I would check if I were you

[Slick_Nick]

I could repair that for you, but it would be a lot of work. I'd cut off the stub, weld on some fresh bar stock to the end, and turn it down on the lathe. Would then need a milling operation for the flat cutout for the clutch piston.

Possible, but not worth it. Would far exceed the cost of a used one. Expand your ebay searches to include both inner and outer clutch cover, most guys will include the arm with that piece, or will sell both covers together, etc.

[DenverKdxRider]

Thanks for the suggestion on searching on ebay. I searched for a KDX clutch cover..and there was a used on that has the accuator..was $80..but at the end of the day..I'll take it!

[KDXGarage]

Ask if the seller will separate them and sell just what you need.

[Slick_Nick]

Ask if the seller will separate them and sell just what you need.

I tried this with a swingarm bolt for an RM125 once. Guy was asking $100 for the swingarm assembly, asked if he would separate just the bolt, he said no. I said ok, I'll buy the swingarm at full price, and told him that I only wanted the bolt, he could just chuck the rest of the swingarm away. Since I'm in Canada, I didn't want to have to pay to ship the whole thing here. He again said no. Ok, TS pal, I turned down my own swingarm bolt from scratch. He messaged me weeks later asking if I was still interested, told him to pound sand.

[KDXGarage]

That sounds odd to not want to sell just the bolt. It is not exactly like selling a shroud brass insert out of a fuel tank.

Congratulations on making your own, as well as being in Canada, so us lower country folks won't bug you to make us stuff. :-)

[DenverKdxRider]

Finally got it. I'll gladly pay $80 to get back on the trails. It's amazing how similar the 94' KLX 300 actuator is to the actual 95-06 actuator..yet it still doesn't fit. Take a look below.



Anyway thanks for the help!

[KDXGarage]

Man! That's close.

Thanks for posting pics.

[SS109]

Hmm, I'm curious what the dimensional differences are.

[KDXGarage]

End result, EBC springs