Starter switch fix
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Thread: Starter switch fix

  1. #1
    Junior Member Kykdaar's Avatar
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    Starter switch fix

    Hi there
    Is there a way to fix the starter press switch when the two contacts seems to be so worn that they no longer make contact?

    Seems an idea might be to either cut the spring a little bit or try build up one of the contact surface areas somehow.

    Anyone did a DIY and can share some advice?

    Thanks

  2. #2
    Senior Member SportsterDoc's Avatar
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    What year TW?
    Most likely not worn, but contacts may be corroded.
    There is not enough current across them to burn them as do the stater solenoid contacts.
    What is the resistance across the switch?
    Have you opened the switch?
    Is there any doubt that the circuit may be open, other than the switch?
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  3. #3
    Senior Member Fred's Avatar
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    Careful inspection, cleaning and reassembly often can restore functionality of most of these TW switches.
    2003 TW200 "Betty Boop"
    2006 TW200 "Nibbler", a.k.a. “Mr.Gizmo"
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  5. #4
    Junior Member Kykdaar's Avatar
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    Quote Originally Posted by SportsterDoc View Post
    What year TW?
    Most likely not worn, but contacts may be corroded.
    There is not enough current across them to burn them as do the stater solenoid contacts.
    What is the resistance across the switch?
    Have you opened the switch?
    Is there any doubt that the circuit may be open, other than the switch?
    A 2003 model
    I have opened it up, not corroded or burnt, but it seems as if the fully compressed spring prevents the two points from making contact hence the thought that one or both may have worn over time to the point where they can no longer close the circuit.

    Have checked the rest of the starting circuit as per manual and everything else is in spec, including the start relay.

    Bike has a kickstart as well (comes standard that way in South Africa), but would like to get the happy button to work again.

    Will re-size pics and post

  6. #5
    Senior Member Gastone165's Avatar
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    Kykdaar, not to change the subject of the post, but you mentioned TWs come with a kickstarter in South Africa. Does that include the current new models? If that’s true, then Yamaha would still be making the kickstarter parts, but just not importing them to the U.S.
    Interesting...
    Now they’ll have to watch for Yamaha Parts smugglers at the airport.
    Ken likes this.
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  7. #6
    Junior Member Kykdaar's Avatar
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    Quote Originally Posted by Gastone165 View Post
    Kykdaar, not to change the subject of the post, but you mentioned TWs come with a kickstarter in South Africa. Does that include the current new models? If that’s true, then Yamaha would still be making the kickstarter parts, but just not importing them to the U.S.
    Interesting...
    Now they’ll have to watch for Yamaha Parts smugglers at the airport.
    Interesting - it seems the latest model on Yamaha South Africa's website is sans kickstarter

    http://www.yamaha-motor.co.za/tw200/

    Will try find out when this happened - they usually had kickstart and e-start
    Miaugi and Ken like this.

  8. #7
    Junior Member Kykdaar's Avatar
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    Folowing the trail -

    A 2004 model locally and my old 2010. Both with front disc and kickstart
    Attached Images Attached Images
    Last edited by Kykdaar; 12-29-2018 at 02:46 PM.
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  9. #8
    Junior Member Kykdaar's Avatar
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    So just to wrap on the starter switch issue - at the end of the day I just lifted the bottom connector out of its plastic recess, flipped it around and re-inserted it back.

    As the bottom connector has a collar that resides in the plastic switch housing it worked without a problem - long side now facing upwards and now easily makes contact with the top connector when slightly pressed.

    Bike start first slight push on the starter switch - happy days

    Top contact.jpg

    Attachment 187950

  10. #9
    Senior Member SportsterDoc's Avatar
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    Good fix.
    2014 Honda CB1100
    2018 Yamaha XT250
    2016 Moto Guzzi V7 II
    2017 Yamaha TW200
    2012 Triumph Bonneville
    2002 H-D Sportster 1200 Sport
    2003 H-D Sportster 883
    1976 Honda CB750F
    1975 Honda CB360
    1970 Yamaha CT1
    1972 Yamaha CT2
    1972 Yamaha AT2/CT2
    1970 Honda SL350
    1970 Honda CL350
    1967 Honda CL160
    1967 Honda CB160
    1962 Honda CA110

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