What is needed other than the case and kickstart assembly attached to the case off of an 87 to retrofit my 04 to kick start. Are there any parts that need to be changed inside the case? Is it as easy as bolt off and bolt on? Is there any concern with taking that engine case off.
Idaho04
Pgilles is correct. It's relatively easy, even if you've never looked inside the sidecovers before. Just pay attention to the parts as they come off of the doner bike and put them back in in the same way. There are probably only one or two components that could get reversed (and not work) if you didn't pay attention. I'd use the new sidecover and punch out the hole as suggested. There is a seal you will want to transfer from the kicker cover. TomYou do not need to replace the case. The 2004 case has a plug where the kickstart pokes through, pop out that plug and you are good to go. If you are taking the guts out of an 87 and putting that into the 04, than you may want to replace the locking-tab washer on the clutch. No other hard parts will be needed, but that wear parts like that locking-tab washer and the gasket for the case would be nice to have on hand. Here are the translated instructions: TW kickstart install instructions
To me it was easy, but that's a subjective subject due to different skill levels. It really is a bolt on deal.
Wow thanks, That makes it very clear. Do you have to do anything special to pull the clutch? Someone said replace the crush washer, which I will get with a couple of seals and a new case gasket, but is there anything special to lookout for when pulling the clutch off?
Thanks
Idaho04
well as i originally stated, my issue was that side gasket leaking that i had to replace, the kick start mechanism is able to be installed and removed without touching the clutch assembly, so i didn't bother with any advance maintainance, one thing i did forget to show is on the kick start assembly in front of the spring there is also 2 washers, one has a locking mechanism and fits over top of the other i think their purpose is to sit against the rubber seal for the kick start to help be oil tight, at the time i didn't replace that either and everything is still fine for me, and my 90 with 16700 kmand don't forget to look at the tw200 maintanince manual, it helped me out a lot throughout the process.![]()
You do not need to replace the case. The 2004 case has a plug where the kickstart pokes through, pop out that plug and you are good to go. If you are taking the guts out of an 87 and putting that into the 04, than you may want to replace the locking-tab washer on the clutch. No other hard parts will be needed, but that wear parts like that locking-tab washer and the gasket for the case would be nice to have on hand. Here are the translated instructions: TW kickstart install instructions
To me it was easy, but that's a subjective subject due to different skill levels. It really is a bolt on deal.
Where can I buy a TW Kickstart assembly?