First I made a stick, then a board, and now a starter
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Thread: First I made a stick, then a board, and now a starter

  1. #1
    Senior Member TW-Brian's Avatar
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    First I made a stick, then a board, and now a starter

    First I made a stick,




    then I made a board,



    and now I've made a starter.

    IMG_1322.JPG

    I wore out my native right knee from years of kicking over old dirt bikes (and playing soccer, and running marathons!) and had it replaced a couple of years ago. Since then I have passed up some good craigslist deals because they were kick only bikes and so I wanted to see if I could come up with some kind of a non leg-powered motorcycle starter. I went online to get some ideas of what others had built for starting motorcycles. I kept some of the good ideas, threw out most of the rest and here is what I built.

    IMG_1331.JPG

    Over the past several months, I have picked up a (real) gas MIG welder, a chop saw, a small mill, some steel and began the development and fabrication process. I wanted something as mechanically and electrically simple as possible, portable, and easy to store. Also, since I am just a beginner garage machinist and welder, the design needed to be something that I could hack out and stick together mostly by myself. Here are some the basic components and fabrication steps that I started with.

    Attachment 188348

    I then bought a heavy duty starter for a big block Chevy motor and began sourcing the drive sprockets and chain.

    Attachment 188350

    Some more fab work and a mock-up of the assembly.

    IMG_0988.JPG

    After welding (and a lot of welding cleanup!).

    IMG_1239.JPG

    Time for initial assembly and functional testing.

    IMG_1244.JPG

    Everything is working, so time to take it apart again, paint and then re-assemble it again. Here is the finshed product, ready to use.

    IMG_1343.JPG

    Here is how it works. Roll the back wheel of the bike onto the rollers. With the bike in second or third gear, pull the clutch in and hold the bike in place with the front brake. Depress the footswitch to get the rear wheel spinning, then let the clutch out until the engine begin to turn over and (hopefully!) fires. Release the footswitch, pull the clutch in and roll the bike off the rollers.

    IMG_1321.JPG

    I learned a lot during this build, mostly by all of the mistakes that I made, but am pretty happy with the way it turned out.
    Last edited by TW-Brian; 01-14-2019 at 09:56 AM.

  2. #2
    GOF
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    Senior Member GOF's Avatar
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    I've seen the board. Gonna steal that idea.
    I get the starter. I'll keep that in mind for the future.
    But just what is the stick for?
    jtomelliott49 likes this.
    1988 Suzuki Savage
    1987 Yamaha TW200

  3. #3
    Senior Member Fred's Avatar
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    And with the wheels you can tow it behind your next bike to restart it when out and about.
    What, no AGM? You remove, or tip the wet cell battery upright when storing that handsome bump-start cart?

    Nicely done Brian, I was impressed with your fabrication skills when I saw it under construction.

    EDIT: Stick is a portable motorcycle stand to carry on the TW. Lifts either the front tire or the rear depending where stick is positioned.
    Last edited by Fred; 01-12-2019 at 04:18 PM.
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  5. #4
    Senior Member TW-Brian's Avatar
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    Quote Originally Posted by GOF View Post
    I've seen the board. Gonna steal that idea.
    I get the starter. I'll keep that in mind for the future.
    But just what is the stick for?
    A trail jack. You can read about it here. https://www.tw200forum.com/forum/tec...ade-stick.html

  6. #5
    Senior Member stagewex's Avatar
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    I've seen those at the racetracks many times. Especially the vintage racers with decompression valves. No such thing as a magic-button.
    Some are homemade some look store bought (not sure what "store")?

    You did an incredibly beautiful job on that one. Really Top-Class.
    2008 Vespa 150"S" (Elec & Kick Start)
    2007 Ural Patrol (2WD, Elec & Kick Start)
    2006 Yamaha TW200 (Elec & Kick Start)
    1995 BMW K75 (Elec Start)
    1991 Honda XR250L (Kick Start Only)
    1986 Yamaha BW200ES (Elec & Kick Start)
    1969 BMW r60/2, US Model (Kick Start Only)

  7. #6
    Senior Member TW-Brian's Avatar
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    Quote Originally Posted by Fred View Post
    And with the wheels you can tow it behind your next bike to restart it when out and about.
    What, no AGM? You remove, or tip the wet cell battery upright when storing that handsome bump-start cart?

    Nicely done Brian, I was impressed with your fabrication skills when I saw it under construction.
    Thanks Fred!

    I was hoping that I could just use a jumpstarter, but they don't seem to work without an actual semi-functional battery in parallel. I also was hoping that I could use one of those plug-in battery charger/engine starters but they don't have enough current to do it. So I went with the wet cell battery. Is there a problem with laying the sealed wet cell battery on its side?

    Brian

  8. #7
    Senior Member TW-Brian's Avatar
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    Quote Originally Posted by stagewex View Post
    I've seen those at the racetracks many times. Especially the vintage racers with decompression valves. No such thing as a magic-button.
    Some are homemade some look store bought (not sure what "store")?

    You did an incredibly beautiful job on that one. Really Top-Class.
    Thanks Stagewex!

    I have seen a few places that are selling ones in the $8-9 hundred dollar range and up. I was mainly looking for project to practice my fabrication and welding skills, but I just couldn't excited about building a welding cart.

  9. #8
    Member Vektor's Avatar
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    I have to admit, I am impressed.
    jtomelliott49 likes this.
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  10. #9
    GOF
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    You do impressive work my friend.
    jtomelliott49 likes this.
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  11. #10
    Senior Member Joemama's Avatar
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    Very nice Brian, it turned out just as you had discribed at your last wrench and ride.
    jtomelliott49 likes this.

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