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Discussion Starter #1 (Edited)
After riding it for 70,000 miles, the engine in my Zongshen ZS200GY-2 finally wore out. I recently replaced the original Zongshen engine with a 1992, Yamaha XT225 engine. I transferred the Zongshen kick starter into the Yamaha engine, and it fit perfectly. If you are interested, you can read about my engine swap at the following thread. :)

Project Phoenix: The YamaZong Rises from the Ashes - ChinaRiders Forums




I can put together a kick starter kit with Zongshen parts. As I understand it, your TW200 bikes need the following parts.

Kick Axle Assembly



Kick Crank Assembly



28T Idler Gear



Finally, you will also need a Kick Shaft Oil Seal. ;)

If anyone is interested, I can obtain these parts from China, and sell you a kick starter kit for a very reasonable price. These Zongshen parts are manufactured to a Yamaha standard of quality. :) I believe the original Yamaha kits had a retail price of $163.99, and were marked up as high as $250. If enough people are interested, I believe I can sell you a complete kit for approximately half the retail price of the original Yamaha kit. Please let me know what you think. ;)

Spud :)
 

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Spud, thanks for following up on this!

I can't tell for sure from the pictures, but a TW kick crank boss may still be needed to allow clearance from the TW's rear brake linkage.

If you are planning to supply complete kits, I would suggest including the gasket for the right (clutch) side cover.

If you are able to do this economically, it will make a lot of people happy :D!

Brian
 

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Discussion Starter #11 (Edited)
When I transferred the kick starter to my 1992, XT225 engine, I noticed a bushing had replaced the 28T idler gear. However, washer #11, washer #13, and the two circlips, part #14, were present.



I removed the outer circlip and washer, and installed the Zongshen idler gear. Then I replaced the outer washer and circlip. :) Looking at the following thread, it seems the TW200 is manufactured in the same manner. Am I correct?

http://tw200forum.com/forum/technical-write-ups/18362-more-kickstart-install-info.html



If I am correct, the parts I listed in the first post should be complete. If I missed any parts, please let me know. ;)
 

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Discussion Starter #12
Spud, thanks for following up on this!

I can't tell for sure from the pictures, but a TW kick crank boss may still be needed to allow clearance from the TW's rear brake linkage.

If you are planning to supply complete kits, I would suggest including the gasket for the right (clutch) side cover.

If you are able to do this economically, it will make a lot of people happy :D!

Brian
You're welcome, Brian. :)

I certainly can also supply a gasket for the clutch cover. It will increase the price a little.

Below is a diagram for the kick starter parts of the year 2000, TW200 motorcycle. What part number is the boss? Either the boss is included in the Zongshen Kick Axle Assembly, or I didn't need it for my Zongshen motorcycle. ;)



I will post some photos of the clutch cover from my Zongshen ZS200GY-2 this evening. I am also willing to take some measurements. However, the Zongshen kick starter perfectly fits my 1992 XT225 engine. :) Does the TW200 need washer #7 and washer #9? My Zongshen engine, and my 1992 XT225 engine do not need these washers. ;)
 

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Discussion Starter #13
I'd be interested if you could find out if it'll fit a tw125 and can ship to the UK.
The Zongshen parts will definitely fit the Yamaha TW200, and the Yamaha XT225 motorcycles. If the kick starter for the Yamaha TW125 model sold in the United Kingdom is the same, the Zongshen parts will fit your bike as well. :)
 

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I'm in...it's not a real motorcycle if it has no kick starter!
 

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This pushed me over. I will take one to finally add kick start. Thanks a lot for doing this.
 

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Discussion Starter #19
Okay, there seems to be a big demand for the kick starter. :) I just need someone to answer my questions, and help me to verify my understanding of the correct parts. ;) I will post a photograph of my Zongshen clutch cover, et cetera, later this evening. However, I think the parts I listed in the first post will work perfectly. The engine in my Zongshen ZS200GY-2 was a virtual copy of the Yamaha TW200 engine, except for a shorter counter shaft. Also, the Zongshen parts fit perfectly in my 1992 XT225 engine. :)

I hope I posted this thread in the correct forum. Once the project gets underway, I suppose I should start a thread in the TW Classifieds Forum. If I posted this thread in the wrong area, I hope the moderators will correct my error. ;)
 

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When I transferred the kick starter to my 1992, XT225 engine, I noticed a bushing had replaced the 28T idler gear. However, washer #11, washer #13, and the two circlips, part #14, were present.



I removed the outer circlip and washer, and installed the Zongshen idler gear. Then I replaced the outer washer and circlip. :) Looking at the following thread, it seems the TW200 is manufactured in the same manner. Am I correct?

http://tw200forum.com/forum/technical-write-ups/18362-more-kickstart-install-info.html



If I am correct, the parts I listed in the first post should be complete. If I missed any parts, please let me know. ;)
Spud, you are correct.
 
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