Kick Start Installation Advice Needed
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  1. #1
    Junior Member d-nix's Avatar
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    One of my first attempts at wrenching my new-to-me 2009 T-dub is to install a kick start kit from North Bay Yamaha. Unfortunately, I'm evidently a slow learner and need a bit of advice.



    After removing the pressure plate from the clutch basket, I attempted to use a 24mm socket to allow removal of the clutch basket. No good, the entire bolt spun (probably, I now believe, because the engine was in neutral). At that time, though, I braced off of one of the 4 posts into which the springs and bolts that hold the pressure plate in place. Snapped off the post (btw, a new one costs $54 from the good folks @ North Bay Yamaha).



    At this juncture, I can't seem to get the engine out of neutral. Tried turning the engine by hand - no go. Replaced the pressure plate (with the 3 remaining bolts & springs)& turned engine over - likewise, no go.



    Any suggestions to 1) Get engine in gear, so I can then 2) remove the clutch basket?



    Also,during all this a single large ball bearing (approx 7 mm) appeared on the ground. Any suggestions where this might belong?



    Thanks for any suggestions. Learning new stuff is fun. Learning the hard way, less so. Time for an attitude adjusting 12oz., I guess. Happy Friday, y'all.

  2. #2
    Senior Member TW-Brian's Avatar
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    Hey d-nix,



    Sorry to hear about your problems. I put a kicker into my 2005 a month or so ago so I know what is involved. I also have a tool that holds the clutch basket so you can get that big nut off without busting your clutch basket (sorry that I am too late for that).



    Here's an offer for you. I have a extra clutch basket that you can have and I would be happy to help you with the install. I'm not too far away from you if you could get your bike up here we could work on it here. If you can't get your bike here then maybe you could swing by and I could show you what to do and send you home with the clutch basket and holding tool.



    Try raising the rear wheel off the ground and moving it back and forth while trying to move the shift lever into neutral. The increased leverage may help. I believe that that ball bearing goes on one end of the clutch actuating rod, but I would have to check the manual for sure. That may also explain if the clutch is not disengaging and not allowing you to get it into neutral.



    Don't get too discouraged, we've all been there before. Let me know how you would like to proceed.



    Brian

  3. #3
    Junior Member d-nix's Avatar
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    TW-Brian,



    Thanks, that's an offer I can't refuse! You're a hero, bro.



    I'd be stoked to bring my bike up to wherever you are, at your convenience (excepting Mother's Day brunch - the cost would be far too high ...).



    Let me know. I'd say PM me, but as yet I'm not sure how that works.

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  5. #4
    Senior Member Rainman's Avatar
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    Quote Originally Posted by TW-Brian View Post
    Hey d-nix,



    Sorry to hear about your problems. I put a kicker into my 2005 a month or so ago so I know what is involved. I also have a tool that holds the clutch basket so you can get that big nut off without busting your clutch basket (sorry that I am too late for that).



    Here's an offer for you. I have a extra clutch basket that you can have and I would be happy to help you with the install. I'm not too far away from you if you could get your bike up here we could work on it here. If you can't get your bike here then maybe you could swing by and I could show you what to do and send you home with the clutch basket and holding tool.



    Try raising the rear wheel off the ground and moving it back and forth while trying to move the shift lever into neutral. The increased leverage may help. I believe that that ball bearing goes on one end of the clutch actuating rod, but I would have to check the manual for sure. That may also explain if the clutch is not disengaging and not allowing you to get it into neutral.



    Don't get too discouraged, we've all been there before. Let me know how you would like to proceed.



    Brian


    Good on you! What an excellent offer. I hope you two can figure it out.
    If you can't find it, grind it

    1990 TW200

  6. #5
    Senior Member joedirt1970's Avatar
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    Quote Originally Posted by d-nix View Post
    TW-Brian,



    Thanks, that's an offer I can't refuse! You're a hero, bro.



    I'd be stoked to bring my bike up to wherever you are, at your convenience (excepting Mother's Day brunch - the cost would be far too high ...).



    Let me know. I'd say PM me, but as yet I'm not sure how that works.


    Brian is a stand up man. He has helped me in many facets of the TW world. What a can tell is that he never expects anything in return, but what I will also tell you is that he is NOT a vegetarian and that he WILL enjoy the occasional Choice cut steak with a cold beverage...
    Hidden Content [/IMG]It's not why, but why not. Do it for the right reason now, versus the wrong reason later.
    Born on a Honda Z50, '78 YZ 80, '79 Husky WR 250

    2008 TDub--Jimbo Shield, Lizard Oil Cooler, Blaster Shock, YZ Hybrid Forks, Supermoto front fender, ATV Bars, Acerbis Brake Cover, 1460 Pelican Case, Cycle Rack, Power Core, Gold Chain.

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  7. #6
    Member BigE_50's Avatar
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    Brian,



    Could you tell me what exactly the tool is that helps you keep the clutch basket from spinning while you take off that 24 mm nut?





    D-nix,



    You aren't alone. I managed to break off TWO screw mounts. Of course, it's equally broken whether it's missing one or two. I knew it was was a bad plan, but I was out of ideas. I wish I'd checked this forum 2 hours ago...

  8. #7
    Senior Member Roninboise's Avatar
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    I went through this process in Feb. I found the perfect tool for holding the clutch basket; a c-clamp visegrip. It worked great for holding while losening the nut as well as tighening and torqueing it.



    Happy Trails All



    Ron in Boise

  9. #8
    Member BigE_50's Avatar
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    When I called North Bay Yamaha to order the broken part, they suggested putting the clutch plates back in, holding the clutch basket with one hand and using an impact wrench. Just tried it and it worked great.

  10. #9
    Senior Member TW-Brian's Avatar
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    Quote Originally Posted by Big E View Post
    When I called North Bay Yamaha to order the broken part, they suggested putting the clutch plates back in, holding the clutch basket with one hand and using an impact wrench. Just tried it and it worked great.


    Big E,



    Glad you were able to get it off using that technique.



    In case you don't happen to have access to an air compressor and impact wrench, here is the tool that I use to hold the clutch boss/basket.



    Here is a link on how it works:



    http://www.rockymountainatvmc.com/do...structions.pdf



    Brian




  11. #10
    Junior Member d-nix's Avatar
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    Brock is right - TW Brian is a generous, stand-up guy. Helped me, a total stranger, for several hours in his shop sorting out the kick starter.



    Thanks, Brian. And Brock, for inside info on thanking Brian.



    Brian's clutch holding tool worked great. I imagine a C-clamp visegrip would also work. From my several early attempts, though, I don't think I could have held the clutch basket firmly enough for an impact driver to release the 24mm nut. It was on pretty tight. Also, spring clip pliers were super helpful (necessary?) to remove & install the second gear needed for the kick start.



    Removing the old engine gasket required grinding it off with an abrasive pad available at the local auto parts store.



    All's well that ends well. Learned a lot. Thanks for the input.

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