1983 kx500 kickstart idler gear

[husky005]

I have bought a 1983 kx500 and it has two teeth missing from the kickstart idler gear. So far I have been unable to find a replacement. I think I have read somewhere that some kickstart parts from later model kx500s can be substituted. Is anyone able to confirm if this is correct and what other parts may also be required.
Any help with information would be much appreciated.
Paul

[Hardo]

Gday Paul. The complete 1985 KX500 Kick assy bolts straight in and you can then use the later alloy kick lever as the shaft is straight and not tapered off. I would assume the 1985 Idle gear is also interchangeable? (not sure on idle gear).

I did the 1985 setup on my 1983 KX500. Works perfect.

I will see if I can upload a pic.... need to remember how....

 

[BAHNZY]

Do a search on this forum. Both Rusty and myself have done the later model conversion on the air cooled KX500's. the main difference between the kick starters is the fixing method to the shaft.

[husky005]

Thanks Hardo and Bahnzy,
I have a complete 87 kickstart shaft assembly. Would this be the same as the 85 parts you have used? I’d like to use the later kickstart lever if this was possible.
I know the idler gear is not compatible as 83,84 and 85 are 27 tooth and 86 onwards are 26. I have been unable to find a 27 tooth gear so  I look like I will have to have a new idler gear manufactured which is a bit expensive - $450.00 plus  gst for one, or $$700.00 plus gst for two. At least that will get me heading in the right direction again.
Thanks again guys,
Much appreciated.

[James P]

Is this part any good to you? https://www.ebay.com.au/itm/Spur-Gear-Idle-KX500-A1-59051-1043-GENUINE-Kawasaki-NOS/282909883385?hash=item41debe3bf9:g:mHoAAOSwHqdawuk4

I can't discern how many teeth it has, but the description only mentions 1983 KX500. This could be because someone has (possibly incorrectly) written "83 KX5" on the packet . Although a quick search revealed that the correct part number is 59051-1107, I did find a suggestion that 59051-1043 was also suitable.

Regards,
James

[husky005]

Hi James,
I’ve been busy with work and have only just seen your post. Looks like I’m too late as the seller has ended the auction, however I have been lucky enough to buy a complete second hand 1985 shaft assembly and the idler gear that appear to be in excellent condition so that should get me going.

If you read this Hardo, what kickstart levers are compatible with the 1985 shaft and are there any years that are preferred. Also are there any clearance problems with the later kickstart levered when used on the air cooled motors.

Thanks again guys, all of you replies help and are much appreciated.
Paul

[James P]

Looks like I’m too late as the seller has ended the auction, however I have been lucky enough to buy a complete second hand 1985 shaft assembly and the idler gear that appear to be in excellent condition so that should get me going.

No worries Paul - glad you got some parts to sort it out. I wonder if someone else (in the same boat as you perhaps) saw the Ebay listing and bought that NOS idle gear !

Regards,
James

[Hardo]

Okay. I remembered how to post pics.

I bought the complete 1985 KX500 Kickstart mechanism. From memory I used the existing 83 idle gear.

The Kickstart lever was bought on ebay from a seller called 'quadchik261'. I just checked and that seller does not have anything currently listed though.

It was listed as a "1985-2004 KX500 Kickstart Lever".

Here are a few pics of it.




Ebay item number 401279227115 would be the same.

Let me know how you go! 

[husky005]

Thanks Hardo,
Thats what I needed to know. I was really worried about the later kickstart lever clearing the cylinder head and the frame, but looking at your bike its fine. Great looking bike.