Hey I have a 2009 KLX250S and the little plastic nub in the starter/throttle housing has broken off now allowing the throttle and house to rotate past the 0 positon and even slide its way toward my barkbusters adding a lot of drag. Trying to see how to convert this to an aftermarket solution and have not been able to find a solution without going to a pumper style carb and using a single cable housing. I have seen the motion pro conversions but nothing for the KLX. Has anyone else broken or replace this before? Thanks

 

The threaded pull cable snapped right where the threads enter the housing on mine. Which part broke? The curved 1" piece inside that line? I saw motion pro sells a new line that comes with that part but its 1.5" shorter as they have 2 part numbers. My throttle is working 5mm play though and exposed wire until i get to kawi shop in person.

 

I’ll see about snapping some pictures tomorrow, my housing is integrated with the kill/start switch so it doesn’t have the dirt bike style threaded ends I am guessing your talking about. My temporary fix was putting some heavy duty electrical style tape under the clamshell and it’s doing pretty well, have to have some serious forward pressure to get it to roll/slide now

 

I have same housing so it was rotating on the bar? My 2 bolts that tighten it and stripping has i had to use alot of force. Ill have to get new bolts at some point. I used thin rubber gasket tape unlike vinyl electrical tape slides easily under there as well

 

Yes, it can even freely slide off the end of the bar if there was enough slack on the cables, the rear side of the switch housing has a plastic tab that slots into a drilled hole on the stock bars that prevents it from moving, mine was snapped off by the previous owner. The only thing holding it in place was the screws for the clamshell. And I suppose I used the same stuff it’s defiantly rubber and tackey on both sides, not sure, got it from the supply room at work. I was looking around and Motionpro makes a “Rev2” kit that converts it into a traditional dirt bike setup but of course they don’t make one for the KLX, maybe by request. Going to run with this tape for a bit and see if it becomes and issue before I spend a couple hundred bucks or hunt down a used housing.

 

Old school called it friction tape.
Works perfectly-I've run mine like that since 2013.

 

I replaced mine with a motion pro unit.. For the switch gear I went with highway dirtbike switches. Switches.

Toph