KDXRIDER.NET

Geesh.... figger it out already..... I need a replacement!

Patience, fellas.
I think I'm going to take a chance on this, I found another example.
This time by Art5, I think he made at least one hybrid:

Ok here we go, you will need a lower knuckle off of an 98/02 kx 250, then you can use either a kx 125 top piece or the 03 and up kx 250 top,

I'm going to buy a knuckle for a 98/02 KX250 and a lever for a 98/02 KX125.

someone go look at pictures of the parts and tell me they are better than OEM or FRP

Your machine is picture-disabled?

The '03 KX250 lever (referenced in the quote above) has quite an angle to it. Not only does the knuckle/lever have to go together and fit on the bike..but the lever has to fit to the bike when it's tucked, too.

My FRP lever just fits between the frame and the pipe (rev)..and that's only with grinding a bit on the heel of the lever.

All that maybe is why you selected the 98/02 KX125 lever over the '03-up 250?

I did a reverse lookup on the kicker SHAFT. Wouldn't that be a hoot to find that the two shafts (KX/KDX) were the same! THAT would answer a lot of questions.

....they aren't......

Oh...every KX kickstart mechanism I've looked at does not callout the lever as a separately available piece.

No, my machine is not picture disabled.
I'm just going to get fired if I spend much more time screwing around on the internet at work. I'm sure Big Brother is watching!

I looked at Ronayers and Bikebandit. It looks like the knuckle is available seperately. It also looks like the lever comes with a knuckle......so I'd be at ~$150.....

I called my local shop today to see if they had a 98-02 KX250 lever assembly on hand. They did not, unfortunately. I need to find out if that knuckle will fit the KDX shaft. I'll go visit and look through thier graveyard of bikes out back.

The KX assemblies look like a better design than the KDX, to me anyway.

I'll make no more comments on this thread until I find out if anything can be done going down this road..............promise!

Re: 'I'll make no more comments on this thread until...'

Me neither!

Look what a CANADIAN did!


http://www.kdxrider.net/forums/viewtopic.php?t=8065

One of his last pictures shows what looks like a KX kicker

Hah! I knew somebody had invented that round thing that makes motion easier. Now I don't have to!

Thank the Canadian:

KarlP wrote:
Mr Canuckhybrid 125-

Tells us about the kick lever on your hybrid!

See the post about the shorty lever in the product review section

http://www.kdxrider.net/forums/viewtopic.php?t=8058

It looks like you have a solution to a vexing problem!

As far as motor position, yeah it looked like the shock spring was up against the air boot enough that the spring motion would work it loose from the carb. That was the OP's original concern.

Its a 98 KX125 kicker but you have to use a 98-02 KX250 boss because of the splines on the shaft.I dont know if you could just get a 250 assembly that would work,but I got the kicker for cheap so I just bought another boss.This is mounted on a hybrid not kdx,just so you

I don't know if the KX125 kicker is stouter than OEM. I think it is. I have one on our KX100 and it looks pretty rugged.

I think I'll go buy a 98-02 KX250 knuckle

Still could be a problem with fit between the lever/the pipe/the frame on the OEM KDX, right?

Maybe to the CR frame/pipe, too.

When is yours going to be done?

Still could be a problem with fit between the lever/the pipe/the frame on the OEM KDX, right?

That's what grinders are for.

When is yours going to be done?

Hopefully I can get a knuckle this weekend. I'm off 'till the 30th.

I'll let y'all know!

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KarlP wrote: Still could be a problem with fit between the lever/the pipe/the frame on the OEM KDX, right?

That's what grinders are for.



Grind this!

Move the kicker forward....

It was for illustrative purposes only..point being there can be a poor enough fit that grinding won't resolve the situation.


Like...in the above CAD drawing (from a not-yet-released beta version program from a Fortune-500 company), rotate the lever far enough forward via the knuckle to clear the frame..and the foot-perch part is going to be pointed in a very wrong direction, not to mention maybe running into the pipe.


My FRP lever clears the KDX frame at the heel by less than 1/4"..and the foot-perch tip clears the pipe by less. One spline either direction is simply not useable.


I don't know what the 250/125 setup will work out to. Karl will purty quick!


...on a hybrid/CR frame anyway.

All right, job done.
I used a '99 KX250 knuckle (herafter known as a "boss") and the '95 KX125 lever off of our KX100.

The boss is narrower so a thick washer of the correct ID and OD has to be put under the nut on the splined shaft.

I had to file a wee bit on the groove on the boss that the screw that goes through the lever rides in. The screw did not want to go through smoothly. Maybe a '98/'02 KX125 lever would not have that issue.

I had to file a good bit off the heel of the lever to get it to clear the frame on my CR hybrid. I don't know if the same issue would be present on the KDX frame - I think not.

The boss to lever joint is a better design than the FRP design, IMO.

The lever itself is weaker than the FRP lever, or at least substantially thinner. Time will tell if it holds up as well as the FRP lever.

I have a document with pictures and words I will be glad to send to anyone, given an address.

How bout throw a picture up on here real quick like?

I'd love to, but can't seem to do so.

If you can I'll send them to you

..all the way through a hard kick.

Fredette's first levers jammed the engine cover at the bottom of the kick....without modification you could end up breaking the cover.

Inda-
I'm doing most of this from work. Our internet policies restrict some of our free time activities.....

CC-
I checked that. The KX boss to lever joint is quite a bit more compact than the FRP joint.

KarlP wrote:Inda-
I'm doing most of this from work. Our internet policies restrict some of our free time activities.....

Well that's downright unamerican!!! SUE!!! Protect your rights under the First Amendment!!