TW200 Forum banner

1 - 11 of 11 Posts

·
Registered
Joined
·
723 Posts
Discussion Starter #1
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/technical-write-ups/70-service-repair-manuals.html and have this open also for reference throughout the process https://www.partzilla.com/catalog/yamaha/motorcycle/2000/trailway-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/technical-write-ups/52081-sub-%24250-all-new-all-oem-kick-starter-yes-%92s-true.html

2.) Assembly and install info I found to be contained mostly within this thread https://www.tw200forum.com/forum/technical-write-ups/13728-kick-start-installation-positioning-pictures.html - Especially useful post for assembly configuration https://www.tw200forum.com/forum/technical-write-ups/13728-kick-start-installation-positioning-pictures-post165213.html#post165213 and another very helpful page in the same thread https://www.tw200forum.com/forum/technical-write-ups/13728-kick-start-installation-positioning-pictures-6.html

Another useful thread https://www.tw200forum.com/forum/technical-help/3645-install-kick-starter-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-CT039-Clutch-Holding/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/technical-help/11475-clutch-adjustment-help.html and here https://www.tw200forum.com/forum/technical-help/7921-clutch-push-rod-adjustment.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/technical-write-ups/129-how-change-your-own-oil.html

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

=)
 

·
Registered
Joined
·
1,865 Posts
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.
 

·
Registered
Joined
·
1,864 Posts
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.
 

·
Registered
Joined
·
1,493 Posts
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?
 

·
Registered
Joined
·
5,843 Posts
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.
 

·
Registered
Joined
·
45 Posts
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.
 

·
Registered
Joined
·
119 Posts
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...
 

·
Registered
Joined
·
723 Posts
Discussion Starter #10
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.
 

·
Registered
Joined
·
119 Posts
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...
Installed!

Hardest part was removing the 13 year old side cover gasket, took almost an hour. Yes I used gasket remover, worthless.

Also make sure to snap-on/hook horseshoe clip on kickstarter axle to gear, don't ask.

Replaced clutch with EBC kit since it was out. My clutch springs had sacked a bit in 12K miles and 13 years of use. Like butter now!

First kick I booted it like my old Honda XR600R. Slammed the lever down so hard I thought I bent the arm LOL. This is one EASY machine to kick over.

I now fear no battery ...
 
1 - 11 of 11 Posts
Top