kx500 broken kickstart

[98kaw5oo]

i went up this past weekend to black lake,michigan-(the absolute best trails in far northern michigan)and broke my kickstart as soon as we arrived,it snapped on the round opening down where it pivots and sits on the boss,i took it over to the local welder($10.00 very fair) and he aluminum welded it but after reinstalling it the weld snapped after the first light kick.i ended up having my buddies push start me and was able to ride all weekend,i also noticed the boss had about 1/4 of the teeth worn away.the boss is about $45.00 and the complete boss and kicklever are $102.00 .i know i can buy a used unit off ebay but i think i would have another problem come sometime.i plan on having a billet aluminum kickstart made and rework the way it slides over the boss unlike the allen wrench set screw and spring and maybe drill through the boss and put a bolt and nut in place.i couldnt find a topic on this and would like to know if anyone has an answer or idea to redoing and making the kx500 kickstart better and longer lasting.i have friends who work at machine shops and can make one.

[stewart]

i like buying the new kx ones ,,they have been improved

[k5abuser]

i watched stewart break his about 3 o'clock today . it helps to keep a few in stock for times like that 

[stewart]

i watched stewart break his about 3 o'clock today . it helps to keep a few in stock for times like that 

they do break some times ...especlly  at 15 to 1 compresion  ,so i keep the  new one in stock..i dont try welding them it does not seem to hold up in that highly stressed area

[98kaw5oo]

thanks for the replies,if they have been improved then looks like a new one will have to do.

[KXcam22]

I am not sure at what year they were improved but after I broke the one on my 92 the replacement was substatially beefier. The original part number gets you the beefy one.  Cam.

[tobys 2 strokes]

i watched stewart break his about 3 o'clock today . it helps to keep a few in stock for times like that 

they do break some times ...especlly  at 15 to 1 compresion  ,so i keep the  new one in stock..i dont try welding them it does not seem to hold up in that highly stressed area

What happens when you weld them? I have been planning on shortning the one on my K5 powered T3 about an inch. I just shortened a KX250 kicker for my ILR330 Is it going to break?

[Mick]

Kickstarters are just another thing KX500s like to break.  It's normal.  I broke three until we made one out of stainless.  And actually the original kicker lasted several more years than the newer versions did.  Having broken two of them in one season, but my KX motor has a bit more compression than stock.  My stainless kicker is over ten years old...and it's showing sings of fatique 

[Speedway73]

On the kick start note.....Will newer kick start units work on older years...like '86/'87 ?? Are the splines the same along with the diameter ??

[BDI]

Stewart, maybe you should talk to Mr C.N.C. about making some billet t6 kickers.

[kaw rider]

what about 4130

[KXT500]

On the kick start note.....Will newer kick start units work on older years...like '86/'87 ?? Are the splines the same along with the diameter ??

the splines are the same but the shape of the kicker changes.

[ReTrO]

I broke my kickstarted yesterday too. Now i cant go riding till next weekend. Does $209 AU sound a bit steep for a new one?? Do any companys make a solid aftermarket unit??

[kaw rider]

If a guy were to make a better part will there be a market for one.

[hughes]

On the kick start note.....Will newer kick start units work on older years...like '86/'87 ?? Are the splines the same along with the diameter ??

I bought a new 04 O.E.M kick starter an it worked great on my 87 500.