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MatsXL
  • Rank:XL Board Member
  • Posts:12
  • From:Sweden

Date Posted:12/03/2017 7:40 PMCopy HTML

Hi,
the kick arm joint was knackered on my 1973 XL250 and no one seem to have them in stock and they are listed as unavailable.
I am new to these bikes but guess that there are loads of other Hondas that I can use the kick starter from?
Any help pointing me in the right direction is appreciated!

Would this one listed as"16.5MM HOLE HONDA XL 250 S 78-81 XR"  fit?

https://www.ebay.co.uk/itm/NEW-KICKSTART-KICK-START-LEVER-ASSEMBLY-16-5MM-HOLE-HONDA-XL-250-S-78-81-XR/192224059463?hash=item2cc1726047:g:c8MAAOSwMmBVqOX5

JKCanuck #1
  • Rank:Bronze Member
  • Posts:27
  • From:Canada

Re:Kick starter compatibility?

Date Posted:12/07/2017 3:41 AMCopy HTML

Unfortunately, the xl250s, 250r, 350r, etc don't fit. The 72 -76 xl250, 74 - 77 xl350 kickers are all interchangeable. Even the 75 - 76 tl250 will work , although the tl kicker is shaped to miss the footpeg. Ebay often has them listed, although usually pricey. I often go to hondarestoration.com and click  on their ebay parts option and find that they sometimes have ebay listings not found on the direct ebay site.  Right now, that site has one listed in Kingswood, Texas for $120. Ouch..  If you're patient, an affordable one will eventually showup. Some other contemporary models, like the MT250 have the same spline structure but are shaped differently, and might work.

MatsXL #2
  • Rank:XL Board Member
  • Posts:12
  • From:Sweden

Re:Kick starter compatibility?

Date Posted:12/07/2017 6:16 AMCopy HTML

Thanks for the good info JK! 
Does the the xl250s, 250r, 350r, etc kicker not fit because of the spline being wrong, or is it the bend of the lever?
I'm thinking that if the splines are right the lever can be reforged into shape.
JKCanuck #3
  • Rank:Bronze Member
  • Posts:27
  • From:Canada

Re:Kick starter compatibility?

Date Posted:12/08/2017 12:48 AMCopy HTML

Mats...  Shape probably doesn't matter, since they're all right side 90degree folding pedals.  If memory serves, the later spline diameters are different, smaller as I recall.  Earlier Cb 350, 450, 360 had different swivel structures but similar splines.  If you have a shop specialising in old motorcycle parts nearby , they might have one of those to try. Other than that, keep an eye on ebay.
MatsXL #4
  • Rank:XL Board Member
  • Posts:12
  • From:Sweden

Re:Kick starter compatibility?

Date Posted:12/08/2017 5:42 AMCopy HTML

No shops like that around unfortunately but I always keep an eye out on ebay and such. 
Maybe I'll take a chance on the listing above just to be sure.. Thanks again for your replies!
tuscarawas #5
  • Rank:Diamond Member
  • Posts:553
  • From:USA

Re:Kick starter compatibility?

Date Posted:12/09/2017 10:06 PMCopy HTML

I thought I would share my experience on this  subject. I have a cb 350/ 360 kick start lever that I have used when I didn't have a stock xl lever. Sort of an emergency piece in case I needed one or my riding friends needed it. The lever looks much sturdier than the stock xl part especially the area where the lever rotates. You just have to position the lever to where it clears the clutch case. The lever looks to be about the same length as the xl350 lever.


tuscarawas #6
  • Rank:Diamond Member
  • Posts:553
  • From:USA

Re:Kick starter compatibility?

Date Posted:12/09/2017 10:27 PMCopy HTML

One other thing I wanted to add is if you use this lever it is a little wider where it goes onto the kick stater shaft. Depending on how big your feet are you might notice it a little more than the stock lever, it was nothing that really bothered me.




MatsXL #7
  • Rank:XL Board Member
  • Posts:12
  • From:Sweden

Re:Kick starter compatibility?

Date Posted:12/10/2017 7:29 AMCopy HTML

 Thanks for the good info tuscarawas. The 16,5 mm splined axle was probably common on early Hondas then. So I'm guessing that several kickers fit the axle but that they differ in how they fit the rest of the bike. Like if they hit the footrest or not and in the case of my '73 I'm guessing the angle of the upper part can possibly come in contact with the carb. Anyway, I bought the black kick lever I posted just to test if it can work. Then I found a original NOS kick joint on ebay that I also bought. :) The splined axle itself was also bent and the idler gear missing a tooth so this cheap little bike is rapidly getting expensive! I was lucky to get a NOS shaft from CMS as it was the last one in stock (hope I don't jinx it now as I haven't received it yet..) All good fun though! :) I'll report back if the black lever fits or not. 
Nvbob #8
  • Rank:XL Board Member
  • Posts:1
  • From:USA

Re:Kick starter compatibility?

Date Posted:12/13/2017 12:56 PMCopy HTML

 MatsXL...Came across this one today:
https://www.ebay.com/itm/HONDA-1972-1975-XL250-K0-K2-NOS-UPPER-KICK-STARTER-LEVER-Part-28301-329-330/362176643518?hash=item54536901be:g:T-QAAOSwYvFZIOS1&vxp=mtr

MatsXL #9
  • Rank:XL Board Member
  • Posts:12
  • From:Sweden

Re:Kick starter compatibility?

Date Posted:12/13/2017 2:33 PMCopy HTML

 Thanks Nvbob, it's already on my watch list! 
That part of my kick lever is pretty good though so I might be ok with just this NOS kick joint I bought from ebay.


MatsXL #10
  • Rank:XL Board Member
  • Posts:12
  • From:Sweden

Re:Kick starter compatibility?

Date Posted:12/18/2017 6:46 PMCopy HTML

New kickaxle and idler gear installed and looking good.



Then the kick lever I linked to in my first post arrived today. Splines were a match and it fit pretty good 



but the swooping bend it has compared to original had it hitting the brake lever.



Good thing I have the NOS kick joint coming from Brazil thru Ebay soon. 

I haven't tried if the '78-81 joint itself fits the stock lever from '73.. I'll do that some day too, just to check. 
EDIT: Nope, that won't work. The crank bosses are very different.


tuscarawas #11
  • Rank:Diamond Member
  • Posts:553
  • From:USA

Re:Kick starter compatibility?

Date Posted:12/19/2017 11:42 PMCopy HTML

That's too bad it won't clear the brake pedal mount.



Is this the part you need ? 
MatsXL #12
  • Rank:XL Board Member
  • Posts:12
  • From:Sweden

Re:Kick starter compatibility?

Date Posted:12/20/2017 5:45 AMCopy HTML

I have that part actually, and it's ok. But the crank boss (or joint as I called it) had very bad splines. 
But I got a NOS from Ebay so it'll be fine anyway. Hopefully I'll get it soon so I can start this bike up!
I bought it without being able to hear it run. It looked so cool I just had to have it anyway. :)

 
MatsXL #13
  • Rank:XL Board Member
  • Posts:12
  • From:Sweden

Re:Kick starter compatibility?

Date Posted:01/29/2018 6:53 PMCopy HTML

Just to round this off, I got the kick axle, idler gear and crank boss delivered and put on the bike a couple of weeks ago.
They, of course, fit beautifully being NOS parts. So I finished the engine work and filled oil. 



Took out the plug and commenced to kick up the oil pressure so it would come out at the castleated nut on the head. It took 85 kicks exactly. 

Then I probably kicked twice as much trying to start it up without any luck -well there was one brief burble of ignition.
The day after I got a new spark plug and it started right up! Sounding like a Briggs & Stratton lawnmover on idle. smiley60

Just need to get a tail light on and also the bash plate needs straightening. Then it's ready for hitting the gravel roads! 

(red flake grips are period parts Made in Japan.  ) 
 




Go soothingly on the grease mud ... as there lies the skid demon! ...





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