Custom Kick Starter Lever Manufacturer
Kick Starter Lever
Frequently Asked Questions About Custom Motorcycle Kick Starter Levers
1. What kick starter lever components can SIMIS manufacture?
SIMIS manufactures OEM motorcycle kick starter lever arms, folding kick pedals, splined mounting bosses, pivot connectors and related metal parts according to customer drawings. Depending on the design, the main lever may be forged from carbon steel, alloy steel or aluminum alloy. Suitable smaller complex fittings may also be supplied as steel or stainless steel investment castings, while approved ductile iron or aluminum castings are considered for compatible applications. Individual parts or specified assemblies are supplied within the agreed order scope.
2. Can SIMIS produce forged steel and aluminum kickstart levers?
Yes. Closed-die forging is a principal SIMIS manufacturing route for suitable kick starter lever bodies and high-load connecting components. Carbon or alloy steel may be selected for robust, compact lever designs, while forged 6061, 6082 or other customer-approved aluminum alloys can be used for suitable lightweight applications. The forging operation creates the main lever shape; the splined shaft interface, folding pivot and any final surface requirements follow the approved drawing.
3. Are cast kick starter levers and folding fittings available?
SIMIS can review approved casting designs. Investment casting is relevant to selected complex steel or stainless steel folding fittings and hinge bodies. Sand or shell mold casting may be suitable for certain ductile iron or cast steel components. Gravity permanent mold casting may be considered for compatible aluminum parts. Cast materials are not automatic substitutes for forged arms or splined bosses subject to repeated starting loads; material, geometry and verification requirements must be approved for each product.
4. Which metals are suitable for motorcycle kick starter levers?
Material options include AISI 1045 carbon steel, AISI 4140 or 42CrMo4 alloy steel, suitable forged aluminum alloys such as 6061 and 6082, and selected stainless steels. ASTM A536 ductile iron, cast steel and A356 cast aluminum are considered only for compatible casting applications. Wrought 6061/6082 and cast A356 are different alloy systems, while 4140 and 42CrMo4 are related but separately specified grades. Every material choice must match the customer-approved component function.
5. What information is required for a custom kick starter lever quote?
Please send 2D technical drawings or available 3D CAD models, the component type, material grade, key mounting dimensions and estimated quantity. For a complete kick starter lever, useful features include the starter-shaft spline or clamping interface, arm offset, folding pivot and foot-contact end. SIMIS can quote a forged blank, casting, finished metal component or specified assembly according to the agreed supply condition. Contact info@simis-group.com.
OEM Custom Motorcycle Kick Starter Lever Manufacturer
A motorcycle kick starter lever, also called a kickstart lever or kick starter pedal, is an external mechanical control used to operate the engine kick-start mechanism. The rider pushes the pedal downward, transmitting force through the lever and its shaft connection to the engine starting mechanism. The lever is distinct from the internal ratchet, return spring, gear train and engine crankshaft.
SIMIS specializes in custom forged alloy steel kick starter arms, forged aluminum kickstart levers, splined mounting ends, folding foot pedals, connecting bosses and selected metal casting components. We manufacture OEM and aftermarket metal parts to customer drawings rather than offering one universal motorcycle fitment.
Kick starter levers can be one-piece arms or assemblies with a folding pedal end. The engine-side connection may use a splined bore, clamping arrangement or another specified attachment. Its geometry is determined by the position of the kick-start shaft, engine case, frame, footpeg and the desired folded and extended positions.
For suitable high-load arms and mounting bosses, closed-die forging is an important manufacturing option. Other metal parts may be cast or fabricated if their material, geometry and operating requirements are compatible. The relevant process is selected for the specific component, not simply because it belongs to a motorcycle.
SIMIS also manufactures custom motorcycle and machinery pedals and automotive and motorcycle castings and forgings for customer-defined projects.
Types of Kick Starter Lever Arms, Folding Pedals and Mounting Parts
Custom kickstart parts differ in arm length, bend or offset, shaft connection, folding action and foot-contact shape. SIMIS manufactures suitable metal components to approved drawings for the intended motorcycle and starting mechanism.
| Kick Starter Component | Typical Features | Possible Production Route |
|---|---|---|
| One-Piece Kick Starter Lever | Solid or shaped arm with a specified starter-shaft mounting end and foot pedal area. | Closed-die steel or aluminum forging for suitable designs. |
| Folding Kick Starter Lever | Lever arm with a pivoted foot-contact end that folds when not in use. | Forged main arm; separate forged or suitable cast hinge fittings. |
| Splined Mounting Boss or Clamp | Engine-side attachment featuring a female spline, slot or clamp connection. | Suitable steel forging or wrought blank with specified finished interface. |
| Kick Pedal Foot Piece | Ribbed, knurled or rubber-covered foot-contact end, depending on the assembly. | Forged, cast or otherwise specified metal foot-end part. |
| Folding Pivot and Hinge Parts | Pivot bosses, pins and connecting fittings for the pedal movement. | Forged steel, investment cast steel or wrought material as approved. |
| Vintage Replacement Lever | Customer-specific profiles or mounting forms for older motorcycles. | Forging or suitable casting based on drawing, material and volume. |
| Off-Road Kickstart Lever | Arm geometry configured for specified enduro, dirt-bike or trail motorcycle packaging. | Suitable alloy steel or aluminum forging. |
Forged One-Piece Motorcycle Kick Starter Arms
One-piece lever arms may combine the mounting hub, arm and foot-contact end into a single shaped metal component. Where the OEM drawing permits, closed-die forging can form the main external geometry from carbon steel, alloy steel or an approved aluminum alloy. A separate steel starter shaft remains part of the motorcycle engine mechanism, not the lever blank itself.
Folding Kick Starter Pedals and Pivot Fittings
Many motorcycles use folding pedals to reduce protrusion when the lever is not operated. The assembly can include a main arm, a pivoted foot piece, a pin and other specified connection details. SIMIS supplies the relevant metal parts and can quote a finished folding lever assembly when the required purchased components and assembly scope are defined.
Spline-Connected Kickstart Levers
The engine-side spline is an essential interface between the lever and the kick-start shaft. The tooth count, form, bore size, axial engagement and clamp geometry vary by engine design. SIMIS manufactures the specified connection geometry rather than claiming that one generic lever fits multiple motorcycles. Adjacent products include custom motorcycle triple clamp yokes and custom front fork metal components.
Closed-Die Forging and Casting Processes for Kick Starter Lever Parts
SIMIS manufactures motorcycle kick starter components through appropriate forging and metal casting processes. Closed-die forging is the primary emphasis for suitable structural lever arms and mounting ends, while steel or aluminum casting is an option for approved smaller fittings and compatible lever designs.
| Manufacturing Process | Suitable Kick Starter Parts | Manufacturing Considerations |
|---|---|---|
| Closed-Die Steel Forging | Main lever arms, splined mounting bosses, solid folding members and certain hinge parts. | Hot-forms carbon or alloy steel in shaped dies for repeat-production forgings. |
| Aluminum Closed-Die Forging | Lightweight main arms and compatible pedal or connecting components. | Hot-forms specified wrought aluminum alloys such as 6061 and 6082. |
| Investment Casting | Complex smaller steel or stainless steel hinge bodies, pedal fittings and shaped levers where approved. | Lost-wax ceramic shell casting for appropriate geometries and part specifications. |
| Sand Casting | Approved ductile iron or cast steel lever bodies and ancillary castings. | Sand molds produce suitable shaped ferrous castings; not a general substitute for a forged high-load arm. |
| Shell Mold Casting | Selected repeat-production small steel or iron lever fittings. | Resin-bonded sand shells used for compatible cast part designs. |
| Gravity Permanent Mold Aluminum Casting | Approved cast aluminum pedal bodies or compatible lever structures. | Metal mold casting uses specified casting alloys rather than wrought forging grades. |
| Pressure Die Casting | Selected noncritical aluminum foot caps and other suitable accessories. | Use requires part-by-part suitability review; no universal structural lever rating. |
Closed-Die Forging for Carbon Steel and Alloy Steel Kickstart Levers
Hot closed-die forging places a heated metal billet between shaped dies and uses pressure or impact to form the required lever shape. It is appropriate for compatible steel parts with curved arms, thicker mounting hubs or integrated pedal sections. Actual strength and fatigue performance depend on material specification, metal flow, geometry and the approved finished condition.
SIMIS offers custom closed-die drop forging and steel forging manufacturing for compatible carbon steel and alloy steel components. A forged blank is not automatically a finished spline-ready or independently certified kick starter lever.
Aluminum Forging for Lightweight Motorcycle Kickstart Arms
Wrought aluminum alloys can be forged into suitable lightweight kick starter lever shapes. Grades such as 6061 and 6082 are considered according to the OEM design and required material condition; 7075 may be evaluated where specifically requested. A suitable alloy and forging process must be established for the actual arm and shaft attachment, rather than selecting aluminum on weight alone.
SIMIS provides custom aluminum forging services for approved motorcycle parts. Forged 6061 and 6082 should not be confused with aluminum casting alloys or assumed mechanically equivalent to a forged steel lever.
Investment Casting for Stainless Steel Levers and Hinge Fittings
Investment casting, also called lost-wax casting, forms compatible metal shapes using wax patterns and ceramic molds. It is an option for selected stainless steel or cast alloy steel lever components, decorative fittings and complex folding pivot bodies. Cast stainless grades must be specified separately from wrought 304 or 316 material designations.
SIMIS supplies custom investment cast components to approved customer requirements. The hinge interface, material acceptance and finished supply condition must be defined for the actual part.
Sand Casting and Shell Mold Casting for Suitable Ferrous Parts
Sand casting or shell mold casting may be used for certain ductile iron or cast steel parts when the design and mechanical requirements allow the selected material. They can offer alternatives for shaped lever bodies or fittings that do not require the same manufacturing route as a forged steel part.
SIMIS offers sand casting, shell mold casting and iron casting services. A ductile iron casting should not be presented as a universal equivalent to a forged alloy steel starting lever.
Aluminum Permanent Mold Casting for Approved Components
Gravity permanent mold casting uses reusable metal molds to create suitable aluminum parts from specified casting alloys. It can be evaluated for compatible pedal fittings and other cast shapes, including certain OEM-approved lever structures. Pressure die casting may be suitable for less demanding accessories, but the suitability of any load-carrying lever requires project-specific approval.
SIMIS provides gravity permanent mold casting for suitable aluminum components. Only the approved material and production route should be shown on the component drawing and quotation.
Forged Alloy Steel, Aluminum and Cast Metal Materials
Kick starter materials must be selected for the component geometry, joint design, corrosion exposure and intended use. SIMIS works with customer-specified carbon steels, alloy steels, wrought aluminum alloys, stainless steel castings and suitable iron casting grades. A forged steel arm, an aluminum folding pedal and a cast iron lever are distinct material applications.
| Material / Grade | Material Family | Potential Kick Starter Application |
|---|---|---|
| AISI 1045 / C45 | Medium-carbon wrought or forged steel; related designations under different material specifications. | Suitable standard forged lever arms, hubs and metal connectors. |
| AISI 4140 / 42CrMo4 | Chromium-molybdenum alloy steels; similar families, not automatically identical specifications. | Approved forged alloy steel arms, hubs and structural connecting parts. |
| 40Cr Alloy Steel | Chromium alloy steel under the relevant Chinese material specification. | Customer-defined steel lever and hub forgings. |
| 6061 / 6082 Aluminum | Wrought, heat-treatable Al-Mg-Si alloys used for suitable forgings. | Forged lightweight kickstart arms and folding components. |
| 7075 Aluminum | Wrought high-strength Al-Zn-Mg-Cu alloy requiring a defined material condition. | Specialized OEM-approved forged lever components. |
| 304 / 316 Wrought Stainless Steel | Austenitic corrosion-resistant steels; strength depends on product and condition. | Suitable forged or wrought custom lever parts and fittings. |
| CF8 / CF8M Cast Stainless Steel | Cast stainless grades; different specifications from wrought 304 / 316. | Selected investment cast hinge fittings and approved decorative or lever parts. |
| ASTM A536 Ductile Iron | Spheroidal graphite cast iron, available in specific mechanical grades. | Approved cast lever bodies or associated fittings where suitable. |
| A356 Cast Aluminum | Aluminum-silicon-magnesium casting alloy, not equivalent to wrought 6061. | Approved gravity-cast pedal or lever-related components. |
1045, 4140 and 40Cr Forged Steel Lever Components
Carbon steel and alloy steel are important material options for motorcycle kickstart levers. AISI 1045 may be specified for compatible standard designs, while AISI 4140, 42CrMo4 and 40Cr are used for suitable steel parts under their relevant material specifications. The alloy and required material condition should be stated in the OEM drawing and should not be changed without customer approval.
6061, 6082 and 7075 Aluminum Forgings
Lightweight kick starter components can be formed from suitable wrought aluminum alloys. 6061 and 6082 are commonly considered for aluminum forgings; 7075 is another option for particular approved parts. The relevant temper and product specification must accompany the alloy grade. These materials are not the same as cast A356 or typical die-casting aluminum.
Stainless Steel, Cast Steel and Ductile Iron Options
Stainless steels may be selected for corrosion-exposed custom motorcycle levers and fittings. Casting can provide compatible intricate shapes using separately specified cast stainless or cast steel grades. Ductile iron can be considered for some approved cast components, but its suitability must be evaluated for the repeated starting forces associated with the actual lever. The material specification must identify a wrought/forged or cast product appropriately.
Applications of Custom Motorcycle Kick Starter Levers
SIMIS supplies custom metal kick starter lever parts for suitable motorcycle restoration, replacement and OEM production projects. Each application has its own shaft interface, clearance arrangement and material requirements.
Off-Road, Enduro and Dirt Bikes
Off-road and enduro motorcycles may use folding kickstart levers with engine-specific bends and foot-contact ends. The parts can be exposed to impacts, dirt and frequent handling. SIMIS supplies forged steel or suitable forged aluminum parts according to the OEM fitment and material specification; no generic lever is assumed to fit every dirt bike engine.
Standard and Commuter Motorcycles
Conventional motorcycles equipped with kick-start systems may use steel lever assemblies containing a mounting hub and foot pedal. SIMIS manufactures customer-defined steel arms, splined connectors and associated parts for relevant production or replacement programs. The finished lever must match the shaft and engine case geometry in the customer drawing.
Vintage and Classic Motorcycle Restoration
Vintage motorcycles often require distinctive lever profiles, splined hubs or folding details. SIMIS can review supplied drawings or dimensioned reference parts for suitable OEM-style replacement components in specified steel, aluminum or stainless steel. Appearance alone does not establish engine fitment or functional interchangeability.
Custom and Aftermarket Motorcycle Projects
Custom motorcycle builders may require particular lever offsets, foot-contact designs, surface treatments or mounting arrangements. SIMIS can manufacture the metal components to approved models and drawing specifications. Any coating, finish, rubber pad or separately purchased assembly hardware must be included in the agreed order scope.
OEM Kick Starter Lever Forgings and Castings Made to Drawings
SIMIS is a metal casting and forging supplier serving custom motorcycle component manufacturers. The manufacturing route is selected according to the drawing: closed-die forging for suitable high-load arms and hubs, aluminum forging for compatible lightweight levers, and ferrous or aluminum casting for selected approved fittings and shapes.
OEM parts can be supplied as forged blanks, castings, finished metal components or specific assembled items when agreed. The engine-side spline, clamping interface and folding pivot are manufactured to customer-defined requirements, with any additional machining, heat treatment, finish or inspection specified in the purchasing documents.
SIMIS does not assign a universal kickstart torque capacity, cycle-life guarantee, proof-load value or certification to every product. Reliability depends on the particular material condition, attachment geometry, engine fitment and the agreed component specifications. Manufacturing a metal kickstarter lever is not the same as validating the complete motorcycle starting mechanism.
The factory photograph below is one of the original body images on this product page and illustrates hot die forging activity; it does not imply that every displayed kickstart lever was made in that particular production run.
Request a Quote for Custom Motorcycle Kick Starter Lever Parts
SIMIS welcomes OEM inquiries for forged steel motorcycle kick starter levers, lightweight forged aluminum kickstart arms, splined mounting hubs, folding pedal components and suitable custom metal castings. To receive a quotation, please provide the following five categories of information:
Drawings: 2D technical drawings or available 3D CAD models, including critical dimensions.
Component type: One-piece kickstarter arm, folding lever, splined hub, foot pedal or pivot fitting.
Material: Specified steel, aluminum, stainless steel or approved cast alloy grade and required supply condition.
Fitment dimensions: Starter-shaft spline or clamp details, arm length/offset, pivot geometry and clearance features.
Purchasing requirements: Estimated quantity, motorcycle or engine application, and whether blanks or finished components are required.
Any additional finishing, inspection or performance requirements can be included in the approved purchasing documents. SIMIS will quote the selected material and manufacturing scope rather than assume a universal fitment or operating load.
Email your custom kick starter lever inquiry to SIMIS: info@simis-group.com.
