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Discussion Starter #1
Here's the back story. There is a part in the KLR600 kick starter that has gone obsolete. It is the guide, part number 13206-1051.

Some time ago Spike613 figured out that the guide from a KX500 might work. It does work after some modification. Spike613 identified the part and I developed the modification process.

The thing of it is, he never got around to obtaining and modifying a KX500 guide for himself. Recently he went looking for one and found out that the KX500 part has also gone obsolete and you can't buy them new anymore. The KX500 guide is part number 13206-1003.

Since he couldn't buy a new KX500 guide he went to e-bay and searched for "kx500 kickstart guide". A couple of the returns for that search were listings for a 13206-009. The sellers list this part as being for the F12MX, KX400, KX450, and KX500. Spike 613 decided to buy one. I saw the picture and thought the bend looked like the bend on the KLR600, which would make this part one that doesn't need much modification, so I ordered one.

Here's the thing. This part is almost perfect. However, it is not for the F12MX, KX400, KX450, and KX500. Those bikes all use the 13206-1003, from 1973 to 2004. This is according to every fiche system that I can access.

When I look up the part number it shows as obsolete/no longer available, but there is no information on what motorcycle(s) this part was used on. This is very useful information because parts are usually listed on e-bay by what motorcycle the part is from, not by part number.

The 13206-1003 has a sharper bend than the 13206-009, so I can't believe that it is an alternate part number for the F12MX, KX400, KX450, and KX500 guide. It has to be for another motorcycle.

Here are a couple of pictures showing the KLR600 (13203-1051) and the 13206-009 part.



Here is the 13206-1003 part, installed before the mod to flatten it out.


Does anyone know where the 13206-009 part comes from?
 

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Tom, Back in the 1970's & early 1980's there were NOT Yet any need for the 4 digit part number suffix.

The 13206-009 is the Original Part number and the 13206-1003 is the up-graded, improved, superseded, also dis-continued replacement.
I'd just looked at my Paper Copy of the 1975 KX400 Parts Catalogue. :)
(Oh, I forgot to say that I checked the supercession in my last ever Paper Price list, date May 13, 2004. :) )

It has always irritated me when they started dropping the line of succession and models used info.
 

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Discussion Starter #3
Thanks, Paul. I figured you might have some insight.

Here's a comparison of the parts. Both were sold to Spike613 as 13206-009 parts, and both had an old-style KHI parts tag showing that number. The one on the left has the same bend as the KLR600 part, the 13206-1051, while the one on the right has the same bend as the 13206-1003 part that is listed for the F12MX and derivatives, '74ish through '04.


The 13206-009 with a shallow bend is as rare as hen's teeth and Spike 613 and I now own all of the known examples in the universe.

All 8 of them...
 

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Tom, Does the steep ramped 13206-1003 Extractor/guide Plate clear the kick gear teeth with sufficient clearance? If so, why bother flattening it? One could just grind the peak of the ramp for a little added tooth clearance, yes?

The steeper ramp of the newer part was probably to ensure that the extractor arm on the ratchet portion could not get caught "tip to tip" and therefore Fail to extract/retract from the always spinning gear.
 

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Discussion Starter #5 (Edited)
This is what I've been thinking about since 9:00 last night when Spike613 sent me the picture.

I'm going to have to get a case down and have a close look at the installation to see if there are any issues with that. The problem is that I don't have a -1003 part on hand to test with, so I have to get one of those first.

What bothers me is why, if they were using the -1003 with it's ~30-degree bend on the KX bikes, did they use the -1051 with its ~15-degree bend on the KLR600? The KX configuration was already in place yet they made a new part for the KLR600.
 

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Tom,
That is like asking, why do they continue to use #92002-1170 Banjo Bolts, when they developed #'s 92150-1641 & 92153-0627 for other applications?

Do you seen what I mean about 'just grind the peak', for additional clearance if needed? There is no loading against it. The spring behind the pawl is the 'engager'. The guide plate is only the 'dis-engager', on the up stroke of the lever.
 

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Discussion Starter #7
...Do you seen what I mean about 'just grind the peak', for additional clearance if needed? There is no loading against it. The spring behind the pawl is the 'engager'. The guide plate is only the 'dis-engager', on the up stroke of the lever.
Yes, I do. I'll check it out.

Why, I have no idea. Spike613 sent me a 12 step program for my addiction and I promised to start going to the meetings.

"1. We admitted that we were powerless over farkling and that our garages had become unmanageable.

2. We came to believe that a motorcycle more powerful and cooler than ours would restore us to sanity.

3. Made a decision to turn our will and our lives to the care of the internet, as little as we understood it.

4. Made a searching and fearless inventory of our shelves and junk drawers.

5. Admitted on advrider.com, to ourselves and to another human being the exact nature of our KLR's shortcomings.

6. Were entirely ready to allow the KLR community to tell us how how stupid we were and tell us to remove all these defects.

7. Humbly asked Eagle Mike to sell us better parts.

8. Made a list of all the pieces that had dropped off due to vibration or that we had chewed up due to our impatience and became willing to replace them all, using loctite.

9. Made an effort to replace them, except where we knew we would screw something else up even worse.

10. Continued to take inventory of what Beemers have that we don't have and when there's a way to mimic it for five bucks, promptly do it.

11. Sought through browsing and forum posts to improve our conscious contact with the Universal Motorcycle Wisdom, as we understood it, praying only that we would finally think of something cool first and have the power to carry it out.

12. Having improved our mechanical understanding as a result of these Steps, we tried to carry this message to KLR owners basking in our sense of superiority."
 

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Discussion Starter #8 (Edited)
Paul,

I softened one of my guides and modified it to a 30° bend, which is pretty much what the -1003 KX500 part is. It cams stuff out of the way just fine and does not interfere with anything.

It looks like that part could work unmodified (except for a bit of grinding to clear the case), but I want to do one final check on the amount of clearance between the ratchet teeth and between the guide and the gear. Also want to make sure it is engaging with the stop properly.
 

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Discussion Starter #10

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trying to be funny...
your 'speak' is way over my head, and my pay grade I'm afraid.
I'm not one to 'craft' parts beyond a little ZipTie Tech, not really.
I've been following this Thread a little bit...
I can't imagine 'crafting/engineering/THINKING/ADDING?' a part to the INSIDE OF MY ENGINE!
I just guess that's one of my Lines in the Sand.
Impressive 'Speak' is what I meant and I need folks like you to learn from, Obi-Wan.
Right?
Thanks for the opportunity to retort.
Best!
 
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