Building a Hybrid Alloy Kick-Starter

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" Look at the size of that kick-starter! " Ok lets admit it if you’re stuck for a hockey stick you can always use a factory KDX kick-starter. They’re longer than most kick-starters and heavier too. There are some advantages of having a long kick-starter; it makes the KDX very easy to kick over which is great for lighter riders. The problem is the longer kick-starter allows for some serious leverage when kicking the engine over. Over time the long, heavy factory kick-starter become fatigued and deforms, the more you weigh the faster it happens. When it does the fit can become sloppy, the lever no longer tucks nicely to the side of the bike and it begins to angle out to the side making it easy for your foot to slip off. If you’re riding in tight conditions its hard enough to clear a wide enough path or lean the bike over far enough to get a good jab at the kick-starter without adding a deformed lever to the problem.   The KX lever greatly reduces the amount of room required to kick the engine over, click here to check it out. Well not to worry there’s a simple fix that is as close as your local Kawasaki dealer.

Building a Hybrid

You can build a hybrid kick-starter by combining the shorter, lighter alloy arm off a 1989 KX125 with the stock KDX mounting hardware. Unfortunately Kawasaki sells it as a complete unit so you’ll have to pay full price and pick up a complete assembly. Dan ( Accutemp ) has once again supplied some excellent pictures detailing what’s involved and illustrating some of the advantages. I can’t say enough good things about this guy. Thanks Dan. It couldn’t be simpler:

1 - You’ll be combining parts from both the factory and 89 KX 125 kick-starter assembly so you’ll need to disassemble both units ( There is no need to remove the factory mounting hardware from the starter shaft. ).  Click here for a detailed view.  Remove the set screw from the side of the lever and remove the spring and ball from the hole. Remove the snap ring from the top of the shaft and pull the lever off.

  2 - Clean the KDX mounting hardware and apply a little grease to the shaft and steal ball. Installation is in reverse order substituting the steal KDX lever with the alloy KX lever.

Note –The nut securing the kick starter assembly in place can work its self free. It a good idea to apply a non-permanent locking agent to the nut to hold it in place. Torque the nut to 49N-m or 36 ft-lbs.

If you have any question fire them off to the JustKDX forum.

If you have any comments or suggestions smack the e-mail icon and send them my way or visit the JustKDX Forum. email@.gif (25222 bytes)

David