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Discussion Starter #1
I am trying to figure out all the parts necessary to make up a kick starter kit. Some say that Yamaha discontinued selling the parts in a kit form but all the parts should be available in separate form if I can find the list. I think the kits came with all the part numbers listed in the instruction sheet.

If anyone has the numbers can you post them here?

Thanks

GaryL
 

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Discussion Starter #3

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Gary I found this on the old TW site,

From Frank Colver

Actually I have no interest in the clutch kit since I'm done with my conversions. It sounds like it is cheaper than ordering individual parts from Yamaha and anyone thinking about adding a kick start should certainly look into it. If one looks at Yamaha's assembly drawing, on their parts web site, it looks like one would need some very expensive parts that are actually already in the bike. I'm just trying to be helpful by providing information to anyone buying the parts individually so that they don't make an expensive mistake.

CORRECTED KICK START PARTS LIST,
REQUIRED TO ADD STARTER TO LATE TW200

1 15A-15660-01-00 KICK AXLE ASSY 12 90468-26122-00 CLIP 1
3 401-15676-00-00 COVER, SPRING 1
4 15A-15666-00-00 SPACER 1
5 90508-26538-00 SPRING, TORSION 1
6 99009-17400-00 CIRCLIP 1
7 90201-175F6-00 WASHER, PLATE 1
8 36X-15641-00-00 GEAR, KICK 1
9 90209-17226-00 WASHER 1
10 93102-17263-00 OIL SEAL 1
11 90201-173F4-00 WASHER, PLATE 1
12 15A-15651-01-00 GEAR, KICK IDLE (28T) 1
13 90214-17028-00 WASHER, CLAW 1
14 N/A CIRCLIP, use the two that are already on the shaft
after removing the spacer that will be replaced by the gear. 2

15 54G-15620-00-00 KICK CRANK ASSY 1
16 54G-15621-00-00 BOSS, KICK CRANK 1
17 90501-12081-00 SPRING, COMPRESSION 1
18 93507-32009-00 BALL 1
19 90152-06010-00 SCREW, COUNTERSUNK 1
20 90338-18014-00 PLUG 1
21 97027-08030-00 BOLT 1
4BE-15462-00-00 GASKET 1

Item nos. refer to Yamaha’s assembly drawing; 3AW7171-0120 1
The drawing can be found on Yamaha's parts web site and should be used during
assembly.
 

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Discussion Starter #5
Gary I found this on the old TW site,

CORRECTED KICK START PARTS LIST,
REQUIRED TO ADD STARTER TO LATE TW200

1 15A-15660-01-00 KICK AXLE ASSY 12 90468-26122-00 CLIP 1
3 401-15676-00-00 COVER, SPRING 1
4 15A-15666-00-00 SPACER 1
5 90508-26538-00 SPRING, TORSION 1
6 99009-17400-00 CIRCLIP 1
7 90201-175F6-00 WASHER, PLATE 1
8 36X-15641-00-00 GEAR, KICK 1
9 90209-17226-00 WASHER 1
10 93102-17263-00 OIL SEAL 1
11 90201-173F4-00 WASHER, PLATE 1
12 15A-15651-01-00 GEAR, KICK IDLE (28T) 1
13 90214-17028-00 WASHER, CLAW 1
14 N/A CIRCLIP, use the two that are already on the shaft
after removing the spacer that will be replaced by the gear. 2

15 54G-15620-00-00 KICK CRANK ASSY 1
16 54G-15621-00-00 BOSS, KICK CRANK 1
17 90501-12081-00 SPRING, COMPRESSION 1
18 93507-32009-00 BALL 1
19 90152-06010-00 SCREW, COUNTERSUNK 1
20 90338-18014-00 PLUG 1
21 97027-08030-00 BOLT 1
4BE-15462-00-00 GASKET 1

Item nos. refer to Yamaha’s assembly drawing; 3AW7171-0120 1
The drawing can be found on Yamaha's parts web site and should be used during
assembly.
That is Golden, pun intended!

Thank you.

GaryL
 
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Gary I found this on the old TW site,

From Frank Colver

Actually I have no interest in the clutch kit since I'm done with my conversions. It sounds like it is cheaper than ordering individual parts from Yamaha and anyone thinking about adding a kick start should certainly look into it. If one looks at Yamaha's assembly drawing, on their parts web site, it looks like one would need some very expensive parts that are actually already in the bike. I'm just trying to be helpful by providing information to anyone buying the parts individually so that they don't make an expensive mistake.

CORRECTED KICK START PARTS LIST,
REQUIRED TO ADD STARTER TO LATE TW200

1 15A-15660-01-00 KICK AXLE ASSY 12 90468-26122-00 CLIP 1
3 401-15676-00-00 COVER, SPRING 1
4 15A-15666-00-00 SPACER 1
5 90508-26538-00 SPRING, TORSION 1
6 99009-17400-00 CIRCLIP 1
7 90201-175F6-00 WASHER, PLATE 1
8 36X-15641-00-00 GEAR, KICK 1
9 90209-17226-00 WASHER 1
10 93102-17263-00 OIL SEAL 1
11 90201-173F4-00 WASHER, PLATE 1
12 15A-15651-01-00 GEAR, KICK IDLE (28T) 1
13 90214-17028-00 WASHER, CLAW 1
14 N/A CIRCLIP, use the two that are already on the shaft
after removing the spacer that will be replaced by the gear. 2

15 54G-15620-00-00 KICK CRANK ASSY 1
16 54G-15621-00-00 BOSS, KICK CRANK 1
17 90501-12081-00 SPRING, COMPRESSION 1
18 93507-32009-00 BALL 1
19 90152-06010-00 SCREW, COUNTERSUNK 1
20 90338-18014-00 PLUG 1
21 97027-08030-00 BOLT 1
4BE-15462-00-00 GASKET 1

Item nos. refer to Yamaha’s assembly drawing; 3AW7171-0120 1
The drawing can be found on Yamaha's parts web site and should be used during
assembly.
I would also add the lock washer that secures the clutch basket.

(I am too lazy to look up the number for that bum GaryL ;)!)
 

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Discussion Starter #7
I would also add the lock washer that secures the clutch basket.

(I am too lazy to look up the number for that bum GaryL ;)!)
Ha! We have both been called much worse and I am a proud MC Bum!

I don't honestly understand the Clutch kit comment and it possibly being cheaper?

GaryL
 
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Ha! We have both been called much worse and I am a proud MC Bum!

I don't honestly understand the Clutch kit comment and it possibly being cheaper?

GaryL
I am not sure what that comment refers to either.

Here is the part that I am referring to. Since you have to remove the clutch assembly in order to install the idler gear, you will probably break off one of the locking ears. If your clutch has already been removed once before, you may not have any locking ears left and will have to order a new lock washer before you can continue the kicker installation. I am pretty sure that the Yamaha kits include a new lock washer for this reason.

I am still not gonna look that number up for you :p!

100_5328.JPG
 

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Discussion Starter #9
I am not sure what that comment refers to either.

Here is the part that I am referring to. Since you have to remove the clutch assembly in order to install the idler gear, you will probably break off one of the locking ears. If your clutch has already been removed once before, you may not have any locking ears left and will have to order a new lock washer before you can continue the kicker installation. I am pretty sure that the Yamaha kits include a new lock washer for this reason.

I am still not gonna look that number up for you :p!

View attachment 20074
I hate those lock rings that are guaranteed to break! I buy new ones with every rear sprocket I replace.

Just because you won't look up that part for me I am tossing a bunch or rotten Empire State Apples at you and I bet Dryden will join this effort to bombard the Left coast! :p

Thanks Brian and Goldenhtr for the great info. I will post if my parts guy can make up kits from the separate parts list at a reasonable price point. Dam this getting old really does suck! I can't remember who I sold my last kick kit too here for $200 but wish I never had sold it. I just keep thinking, this will be the last TW I buy, fix up and flip and then another one falls into my garage. I did kind of fall in love with the XT225 I got with the last TW deal and neither one has a kicker being 2006 models and both with under 100 miles on them. Being just a part time and very local rider I honestly don't need a kicker but my wrenches are calling me to get off my ass and to some fun work.

GaryL
 

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Discussion Starter #11
Not sure either about the clutch kit referance but you can read the whole thread here.

corrected kick start parts list - Yamaha TW200 Trailway Discussion Forum
OK, so the clutch kit is a reference to all the parts shown in the standard parts breakdown shown for the entire right side under the case. Bikes after 2001 come with all of those parts except just the ones related to the kick start mechanism. Looks like they took the entire kick gear shaft and everything on it right out, added a spacer and plugged the hole.

GaryL
 

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I've been thinking about going this route as well. Looking at the parts diagram, #15 "looks" like it should include #16-21, so perhaps those parts would need not be ordered.

Comments?
 

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Discussion Starter #13
I've been thinking about going this route as well. Looking at the parts diagram, #15 "looks" like it should include #16-21, so perhaps those parts would need not be ordered.

Comments?
I believe you are right that #15 is the complete assembly with the bolt and should just need to be installed on the shaft.

GaryL
 

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If that is indeed the case, I come up with $228.56 at the boats.net site. Not that bad, especially if out in the boonies!
 

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Discussion Starter #15
If that is indeed the case, I come up with $228.56 at the boats.net site. Not that bad, especially if out in the boonies!
If that is accurate and they can actually get all the parts then that is a great price. Let us know if you can confirm that number.

GaryL
 
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