How to Remove Starter Motor
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  1. #1
    Senior Member Snake2715's Avatar
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    Ok simple really, I want to paint my starter motor.. for some reason my new TW has a rusty case.



    I see two bolts on the right side (sitting on the bike). I took those out and figured it would be like a car and would come right out, it didnt and I dont want to pry on it.



    Do I have to remove the left side (while on bike) of the crankcase cover or something to get it out?



    I have looked at the parts diagrams and its not very clear to me.



    Thnaks for any input.

  2. #2
    Senior Member Rainman's Avatar
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    The manual says that you have to remove the front stay (motor mount) but you don't. Remove the two bolts (one should have the negative wire attached to it) and remove the screw that attaches the positive cable. The motor should just pull straight back and out. You might have to wiggle it a bit, but it should come out. The part of the starter thats inside the motor is just a splined shaft that spins a gear inside the left side cover. When you reinstall, use a little grease or oil or whatever on the o-ring to ease installation.
    If you can't find it, grind it

    1990 TW200

  3. #3
    Senior Member Snake2715's Avatar
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    ok great that is how I thought it should come out, but didnt want to break it.



    I was worried it was splined into another gear and then had a pin holding it behind the left hand case cover or some weird thing.







    So to confirm I dont have to remove the bolts on the left side of the motor (on the bike). Just the two bolts like you mentioned.



    Thanks

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  5. #4
    Senior Member Rainman's Avatar
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    Yeah, just the two bolts. I ran out and took some pictures of my parts bike for you.



    Remove two bolts, negative and positive wires:





    Should pull out. May take a little wiggling.







    End of the starter motor that goes into the engine:





    Here is a picture from the left side of the bike. This is where the starter meets up with the starter gear (or whatever its called). My finger is pointing at the splined shaft of the starter. Never mind the ziptie, its not a stock part!:

    If you can't find it, grind it

    1990 TW200

  6. #5
    Senior Member jpuck's Avatar
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    rainman it is people like you that make this forum so nice.

  7. #6
    Senior Member Snake2715's Avatar
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    Wow Rainman above and beyond. Thanks so much for the reply and then the follow up with pictures.



    Again I figured that was the deal, but I have assumed before to miss a C Clip and then tear something up (another project in the past), I try to take time to ask or research if it doesnt immediately do waht I think it should.



    Again thanks!

  8. #7
    Senior Member Rainman's Avatar
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    Thanks for the kind words guys. You are very welcome.



    If you can't get the starter out, try using a flat bladed screw driver to gently pry the starter out by wedging it between the motor and "ears" of the starter motor case (where the bolts go through). Don't pry very hard because you'll chip something or even worse, break something.
    If you can't find it, grind it

    1990 TW200

  9. #8
    Senior Member Snake2715's Avatar
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    Ok it came right out when I got home. quick sand and some high temp flat black paint and it went right back in. I did lubricate the oring and clean the general area up. Had a rock wedged in there pretty good from a trailride with previous owner.







    Quick and easy job that helps the appearance.



    Thanks to all again.

  10. #9
    Senior Member Rainman's Avatar
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    Alright! I am glad you got it out! Its funny you mentioned you had a rock wedged in there as I always have something stuck in there after every ride. It may be a rock, stick, sagebrush or just clogged with mud. A pick and needle nose pliers are your friends for wedged rock removal.
    If you can't find it, grind it

    1990 TW200

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