Kick Start Install - Just Some Notes and Thoughts
Close
    
    
Page 1 of 2 12 LastLast
Results 1 to 10 of 11
Like Tree30Likes

Thread: Kick Start Install - Just Some Notes and Thoughts

  1. #1
    Senior Member Sthrnromr's Avatar
    Join Date
    Oct 2018
    Location
    Rural, South Carolina
    Posts
    436

    Kick Start Install - Just Some Notes and Thoughts

    I figured as much as I searched and looked at posts when tackling the kick start install myself, I would post some notes and thoughts from the install process here. I see a lot of people have been buying kits from Sebastian and other places lately and will probably start the procedure soon, so maybe some additional info here may help. My suggestion is to read and click through this post in its entirety before starting the job.

    NOTE: I purchased all items from boats.net, partzilla and amazon and did not purchase a kit, so my thoughts and notes may be different:

    0.) Download the TW200 manual https://www.tw200forum.com/forum/tec...r-manuals.html and have this open also for reference throughout the process https://www.partzilla.com/catalog/ya...tw200m/starter

    1.) I ordered parts from this list. Most parts came from boats.net but a few had to be sourced elsewhere for in-stock availability, but I did find this list to be complete. https://www.tw200forum.com/forum/tec...%92s-true.html

    2.) Assembly and install info I found to be contained mostly within this thread https://www.tw200forum.com/forum/tec...-pictures.html - Especially useful post for assembly configuration https://www.tw200forum.com/forum/tec...tml#post165213 and another very helpful page in the same thread https://www.tw200forum.com/forum/tec...ictures-6.html

    Another useful thread https://www.tw200forum.com/forum/tec...ter-tw200.html and some useful photos TW 200 Kick Starter by Rick Robinson | Photobucket

    3.) CLEAN YOUR BIKE before starting any of this install. You don't want dirt in the case once you open it.

    4.) Buy this tool. EBC CT039. Seriously. I have used rags, wrenches, vice grips, broom sticks etc. This tool makes the clutch removal the easiest part of the job. It is worth the price. Easily https://www.amazon.com/EBC-Brakes-CT.../dp/B006O72S6M

    5.) While you are in there replace the clutch and springs. Use an upgraded kit such as one from Barnett, Vesrah or EBC. All of which will be an upgrade with the stiffer springs.

    6.) This also gives you the perfect opportunity (whether replacing the clutch or not) to properly adjust the clutch. Great threads for this here https://www.tw200forum.com/forum/tec...ment-help.html and here https://www.tw200forum.com/forum/tec...djustment.html

    7.) Fuck that gasket. Seriously and (non-millennial) literally the WORST part of the job. I am pretty sure that instead of grease or oil to hold the gasket in place, the last person to open that case (previous owner or the factory) used a combination of super glue, loctite, 3M industrial adhesive all mixed with JBWeld to adhere that gasket to the case. Removing it without damaging the aluminum SUCKED. Prepare for this, take your time and soak it if needed. Then do yourself a favor and use a little grease for the gasket seal and any future removal. Honestly this part sucked. But all worth it in the end for a much better functioning clutch and a working kickstart.

    8.) Just an observation, but I think the kickstart spring is a bit lightweight. Yes it is installed correctly with the proper pre-tension. I re-checked this numerous times. The kickstart does spring back, but it's weaker than other kicker bikes I have had. I'll get used to it.

    9.) Be sure to follow proper oil change procedures including the proper filter (4 holes same side), proper oil (your choice, not going there in this thread), and weep bolt verification. All well documented here https://www.tw200forum.com/forum/tec...r-own-oil.html

    10.) Enjoy your kick start and if anyone gets stuck, refer or respond to this thread or ping me.

    =)
    2010 TW200 - The Goat
    Triumphs
    ATVs
    Way too many past bikes to list

  2. #2
    Senior Member Miaugi's Avatar
    Join Date
    Oct 2017
    Location
    Alfred, On
    Posts
    455
    Thanks for putting this altogether. This is on my to-do list but there are other projects ahead of this one.....but one day.
    Sthrnromr likes this.
    Hidden Content Sold...Oct 2018......'01 F650GS

  3. #3
    Senior Member Tweaker's Avatar
    Join Date
    Dec 2015
    Location
    San Diego
    Posts
    1,854
    This is a great thread.

    One thing I recommend doing ,and I didn’t read all of the posted threads to see if this is covered, is to place the kick start arm on the shaft and slowly move it to check the correct action before putting on the side case. Removal of the spark plug makes this easier. Some have misinstalled ,and I almost did that on my first install of two, and have broken a boss in the case. You’ll be unhappy if this happens to you.
    ”Everything You Know is Wrong”

    ” How Can You Be in Two Places at Once When You Are Nowhere at All?”




    Twin 2014 TW200's made side by side on the assembly line, Moose rear racks, Protaper ATV high bars, DG oval pipes, kick starters, rejetted carbs, 130 main jets, 2 -3 -.020 shims on the needles and @ 2 1/2 turns on the pilot screw, #34 pilot jets, Acerbis hand guards, Shinko 241 front tires, modified Krator foot pegs, 14-55t sprockets, Ricochet skid plates and 90 degree fuel filters.

  4. Remove Advertisements
    TW200Forum.com
    Advertisements
     

  5. #4
    Senior Member stagewex's Avatar
    Join Date
    Jun 2016
    Location
    New Rochelle, New York
    Posts
    1,629
    Yes, the kickstart spring/tension definitely seems much more lightweight than my other bikes. And a much shorter kick-throw if that's the correct term.
    Sthrnromr likes this.
    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)

  6. #5
    Senior Member Peterb's Avatar
    Join Date
    Apr 2011
    Location
    North Bay, Ontario, Canada
    Posts
    1,453
    Just switching the kicker from my 99 to my 15 and have a question. I checked the clutch plate adjustment before I took them apart to see if I would have to adjust it while I was in there and both were fine. After removing both clutch plates I notice that you can jiggle the adjuster stud/nut in the clutch plate. Is that normal or should I take them apart and have a look?
    Last edited by Peterb; 03-17-2019 at 05:15 PM.

  7. #6
    Senior Member TW-Brian's Avatar
    Join Date
    Dec 2010
    Location
    Pleasanton, CA
    Posts
    5,549
    Quote Originally Posted by Peterb View Post
    Just switching the kicker from my 99 to my 15 and have a question. I checked the clutch plate adjustment before I took them apart to see if I would have to adjust it while I was in there and both were fine. After removing both clutch plates I notice that you can jiggle the adjuster stud/nut in the clutch plate. Is that normal or should I take them apart and have a look?
    That is perfectly normal.
    Peterb likes this.

  8. #7
    Senior Member Peterb's Avatar
    Join Date
    Apr 2011
    Location
    North Bay, Ontario, Canada
    Posts
    1,453
    Thanks Brian.

  9. #8
    Member OldMan's Avatar
    Join Date
    Apr 2019
    Location
    Rural SE North Carolina
    Posts
    37
    Sthrnromr - I am wondering how much the parts set you back for the complete job (if you kept track) and also about how many hours it took you - I know how long is relative to what each of our mechanical abilities are, just wondering what it took you time wise.

  10. #9
    Member elBuro's Avatar
    Join Date
    May 2013
    Location
    Boise foothills, Idaho
    Posts
    77
    Quote Originally Posted by OldMan View Post
    Sthrnromr - I am wondering how much the parts set you back for the complete job (if you kept track) and also about how many hours it took you - I know how long is relative to what each of our mechanical abilities are, just wondering what it took you time wise.
    I just purchased ALL the parts for the kickstarter from Partzillia last month and the total was just over $300.

    Installing in the next week or so...
    Last edited by elBuro; 05-05-2019 at 08:55 PM.
    goldenhtr likes this.
    2006 TW200 CA version

  11. #10
    Senior Member Sthrnromr's Avatar
    Join Date
    Oct 2018
    Location
    Rural, South Carolina
    Posts
    436
    Quote Originally Posted by OldMan View Post
    Sthrnromr - I am wondering how much the parts set you back for the complete job (if you kept track) and also about how many hours it took you - I know how long is relative to what each of our mechanical abilities are, just wondering what it took you time wise.
    Hello OldMan,

    I sure did. Please see the two attached screenshots. I keep track of everything lol. The one part that I had to get from an Amazon seller, bc Boats.net did not have it in stock. Details for both orders are attached. Grand total for all parts shipped to my door with taxes and shipping included was exactly $276.52.

    As for the install, it honestly didn't take many hours at all. The most time consuming parts were cleaning the bike prior (highly recommended) and scraping the damn gasket off cleanly to prep for the new side case gasket. So, I would guess somewhere around 3-4 hours total with cleaning and scraping, give or take(ish). With all the notes and pictures on this site and documentation from my/this post and all links, it's not a bad job. Especially when you have a great group willing to help you out if you get stuck on anything. I hope this helps.

    Screen Shot 2019-05-06 at 11.12.33 AM.png

    Screen Shot 2019-05-06 at 11.14.44 AM.png

    Cheers.
    jtstdub, OldMan, Mel and 1 others like this.
    2010 TW200 - The Goat
    Triumphs
    ATVs
    Way too many past bikes to list

Page 1 of 2 12 LastLast

Sponosred Links

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •  

Similar Threads

  1. Amatuer kick start install results in oil pump shredding!
    By zmonster in forum Technical Help
    Replies: 20
    Last Post: 06-25-2016, 09:17 PM
  2. Replies: 27
    Last Post: 05-31-2016, 08:44 PM
  3. kick start just install!!
    By Sam in forum General Discussion
    Replies: 14
    Last Post: 07-26-2015, 10:21 AM
  4. Spare battery vs. kick start install
    By Highway 61 in forum General Discussion
    Replies: 9
    Last Post: 04-03-2015, 03:58 PM
  5. Mod progress and notes...
    By ActionDeath in forum Performance and Customization
    Replies: 12
    Last Post: 05-11-2014, 08:56 PM