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  1. #1
    Senior Member Tiny-Wheel-200's Avatar
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    Kickstart question

    Hey I have a 2007 bike and an older engine with kickstart. I want to swap tge right case and kickstart from the old engine onto the 2007 engine. Has anyone done this and id love to hear what anyone has to say about this and any thing I should be aware of vefore I embark. Thanks in advance

    Sent from my LML211BL using Tapatalk
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    Senior Member Peterb's Avatar
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    I want to do the same with my 15.
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    Senior Member jtomelliott49's Avatar
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    There was once a member on here who did quite a few of these alterations back when the kick start kit was still available. IIRC you don't have to have an older pre 2000 sidecover, he would drill out the hole in the sidecover and put a new seal in there. Someone will chime in who knows more about this. TWBrian has done this I think.
    Tom in Wichita

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    Senior Member Tiny-Wheel-200's Avatar
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    Quote Originally Posted by jtomelliott49 View Post
    There was once a member on here who did quite a few of these alterations back when the kick start kit was still available. IIRC you don't have to have an older pre 2000 sidecover, he would drill out the hole in the sidecover and put a new seal in there. Someone will chime in who knows more about this. TWBrian has done this I think.
    Right I should clarify I dont have the kit I just have a complete engine from a 91 that has other issues so I want to use the right case and kickstart mated to tge 2007.

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  7. #6
    Senior Member TW-Brian's Avatar
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    Quote Originally Posted by Tiny-Wheel-200 View Post
    Hey I have a 2007 bike and an older engine with kickstart. I want to swap tge right case and kickstart from the old engine onto the 2007 engine. Has anyone done this and id love to hear what anyone has to say about this and any thing I should be aware of vefore I embark. Thanks in advance

    Sent from my LML211BL using Tapatalk
    This is how I did my first kickstarter installation and I feel this is the best possible way to do one. You get to disassemble a working kickstarter from the donor engine and then reassemble it in the recipient engine. Your 2007 engine side cover just has a plug in it that can be pushed out so you can use whichever side cover that you wish to use.

    The most difficult part will likely be removing the old gasket from the engine case and/or the side cover. Also, you must be careful removing the inner clutch basket so you don't break one of the mounting posts. This is best done using a clutch holding tool, or can also be done using an electric or air powered impact wrench.

    If you PM me with your email address, I can send you some instructions that I prepared for the removal of the kickstarter assembly.

    Brian

  8. #7
    Senior Member stagewex's Avatar
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    TW-Brian is wise. He helped me along with my kickstarter with instructions and advice. I had the "kit" but you are actually in better shape, your '91 engine already has 98% of what you need.

    No drilling or swapping cases either. Already have the pop-out on your '07 case where a kickstarter SHOULD be.

    You'll need a new gasket like Brian said and the little plastic plug to cover the kickstart spline. Keep it clean. That's pretty much it
    I do a lot of ordering through Babbitts On-Line but Revzilla, Tucker-Rocky, Yamaha on-line or your dealer can get these parts easy. Mine came in 3-4 days. Good Luck.


    Gasket-Kicker-Kit.
    IMG_6264.JPG


    Gasket, really all you need if the rest of the Kick-Start mechanism is in working order.
    Attachment 188786


    Installed with the exception of the little plastic spline plug. The one on the '91 will probably break.
    IMG_9559.jpg


    Not to worry, they cost $3.49.
    IMG_9561.JPG


    Go kick-start your bike.
    IMG_9564.jpg
    Last edited by stagewex; 01-22-2019 at 08:30 PM.
    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)

  9. #8
    Senior Member Donzo's Avatar
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    I did mine recently. TW B helped me also...he be Da Man.
    Here's a pic of the clutch wrench in action and the kit with wrench. Worth it.
    Attached Images Attached Images

  10. #9
    Senior Member Donzo's Avatar
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    And stiffer clutch springs in pic. Why not while open

  11. #10
    Senior Member stagewex's Avatar
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    That's a great picture Donzo.
    Yes, the Clutch-Basket holding tool. Not absolutely necessary but a good thing to have.

    A whopping $13 or $14 bucks.


    Holding mine for a friend who is installing the kit in his xt225.
    IMG_0399.JPG
    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)

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