Maintenance & Technical > KX500 Original

Busted Kickstarter lever

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Hogwylde:
I seem to remember reading somewhere (here I think before the site switched over) that the kickstarter lever was notorious for breaking as the worst possible moment.  (Happened to me today, hour and a half drive and $15 bucks to get in and all I get to do is piss in their port-a-john.  d**n thing broke trying to get it started first thing!)

Anyways, I seem to remember the advice was to get a kickstarter lever assembly from a newer model (98 and up) KX500 because they were re-designed and are stronger.  Is this true or am I imagining things?  I did check and the part numbers are different for the pre-98 models than the post 98 models.

Thanks all!

demographic:
I thought it was the 2002 and later ones.

Anyway I am pretty sure the newer part number supersedes the old one anyway so have a look on buykawasaki.com and get the new part number then order it.

I have not done it myself yet so perhaps it might be better to wait till somebody who has tried it confirms what I have said.

Anyway, Good luck

beastrider500:
Happened to me too. I had to push the beast about a half mile back to the truck. Talk about fun! Then of course you get the helpful fellow that suggests bump starting it. :evil:  Can you bump start a 500? I can't. Now every time I start the beast I wonder if it's going to make that funny noise again. So far it hasn't though.

John:
Tough luck!

Mine broke as well. My bike is an 89'er and I have changed to the newest possible kick start (2002). Fits alright and it seems to be a more robust design.

/John

Rick:
Yup, everyone will eventually have this problem, and as everyone who has this problem will attest, it happens at the worst possible time!  My first one happened out in the middle of nowhere.  The second one happened on the start line of the first race of the season, but by that time, I had a spare in the van, so all I lost was time.  Didn't get started until the the beginner wave left, so spent the whole day passing people.  Still won first place on the year (and 4th overall I might add) for the regional series in the Open Expert class, but played catch-up all year because of that dang kick start lever.

When the 2002 models were release, I noticed immediately that the kick start lever had been modified, but since I was buying a new bike, didn't bother to upgrade the 2001 I was selling.  I think you can either replace the whole thing, or just the aluminum lever, but will need to check your particular bike.  I also believe the part numbers have all been changed to the new lever, but you will want to make sure.  No sense buying the old one, just to wonder when it will break again.

As a final note, a KX500 is relatively easy to bump start......if you have a weighted flywheel.  If you don't, you'll need to tow it with the truck to get 'er started.

Rick

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