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Post Info TOPIC: Kick starter information


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Kick start return spring
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Hi Mark

The kickstart spring on the TTR is a pretty hefty bit of kit and I have never come across a broken one.

If you wanted to get the part in then its part number is 90508-324B5. However, it is very unlikely that even a big Yamaha parts dealer (try MotoWard or Fowlers) would have it in stock which would mean a delay in getting it to you.

As Jarrah points out, the most likely cause of a floppy kickstart arm is a problem with the spring's retaining pin as shown repaired in the pic below. Fingers crossed that isn't the problem with yours!

You can only check by pulling the clutch cover.

Brian

Kickstart spring retaining pin.jpg

 

 



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Starter "clonk" and kick start conversion
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Hi Folks,

I've read Brian's excellent kick start conversion topic, but I understand that the kits are 1. V pricey, and 2. not available any more. So, is there any other engine whose parts would fit as TTRs for breaking are pretty rare. I was thinking YZF or WRF maybe ?

Also how bad a clonk noise does the starter make if it's on it's way out ?

Cheers,

Mike



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Super Guru

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A couple of owners tried similar looking kickstarts from other Yamaha dirtbikes including an XT350 I think. No-one has found one that fits so far.

If the clonk makes you wince then time to change that sprag! Not worth taking chances. The cost of new parts if the sprag kicks back strongly (starter motor and starter gears at least) make it not worth taking a chance.

Brian



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Super Guru

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TTRfan wrote:

A couple of owners tried similar looking kickstarts from other Yamaha dirtbikes including an XT350 I think. No-one has found one that fits so far.

 

Brian


 What are the kick start part numbers....

Do a search as yamaha usaly don't change the part numbers other the the last 2 or 3 didget pre-fix

if the same part is used on diffrent models..

IE.. the Rekluse conversions I have done on the TTR & XTR as both bikes use the same clutch parts numbers as the

TTR250/WR250F/YZF250 use the same plates & part numbers , same with the XT660R/WR450F/YZF450 same part numbers..

So do a part number search on models that could use the same parts... XT250 , XT225 , WR250F , TW200 , ETC

since the TTR has been around for a few years now it could be a older model that is compatable...



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Super Guru

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Quite a few of the part numbers have the 4GY prefix which tends to indicate they are unique to the TTR250. 

Kit kick start doc page 1.jpg

Kit kick start doc page 2.jpg

Kit kick start doc page 3.jpg

Kit kick start doc page 4.jpg

Yamaha OEM kickstart_kit.jpg



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Super Guru

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Just done a search......

The main kick start shaft part 4GY 15660-00

I left out the 4GY and put in yamaha 15660-00 into google

got over 20 diffrent models that have a kick shaft with the 

number 15668-00

rangeing from 1980 XT/TT250 up to WR/YZF250

part number 3Y1- 15660-00 is the most common..



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Super Guru

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I am not entirely convinced that works Pete. I think the model prefix is the key and the second part probably just means kickstart shaft.

For example, look at this ad on eBay and the part on offer doesn't look at all like the TTR shaft cry

It would be good to be shown I am wrong - who's going to try? biggrin



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Thanks guys, and yes Brian, I think you're right. One of the parts that comes up is for the TR 125, and same number brings up RD250 and 350.

It's just that the WRF and YZF engines look so similar, but I guess they're different hmm



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RE: Kickstart lever restraint!
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It's all about power to weight on a small capacity machine. I removed my kickstart almost as soon as I got home after buying my 2011 machine. do you REALLY need it onroad only?.

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Worth having it for a back up, nice to know I got a back up if battery is toast or need to turn bike over a few times saves using the electric start and wear on sprag clutch

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If your TTR doesn't have a kickstart then it's worth carrying a pair of small motorcycle jump leads such as here 



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Super Guru

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how often do you use the kick start?
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mossman asked the question about how often we use our kick starter .

My bike is five years old and I cable tied the lever to the frame when I bought the bike and has never been used .no trouble starting hot cold or after being upside down .

Any other feed back 



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RE: how often do you use yhe kick start
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Never, that's what the button is for

having said that i'm going to give it a go and see how easy it is just in case I have a flat battery sometime

Couldn't hurt to get some kick start practice



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I use the TTR250 kick start quite a lot.
I also always kick start my WR250F (because of electrical problems - too lazy to fix its electric starter).

I can say that the WR is much easier than the TTR (presumably due to good auto decompression).

The TTR seems physically harder, and needs more attention to detail (starting at the right point in the stroke).
Hot restart is usually easy enough but when I try a cold kick start, I typically revert to the button after 1 or 2 failed kicks.

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Super Guru

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how often do you use the kick start?
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I have been thinking hard about this and can't honestly recall the last time I used the kickstart to actually start a TTR although I know I did a long time ago! I tend to use kickstarts occasionally to turn the engine over when doing engine work.

I do recollect that the kickstart is very low geared and it is difficult to get a good spin on the engine.

Brian



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When my right leg was better than now (over 2 years ago) I could ONLY start mine on the kickstart when the engine was warm. bleh

I tried many times when it was cold but ultimately had to use the button. hmm

Now I don't bother using the kicker at all.

As the saying goes - why have a dog and bark yourself? confuse

Martyn



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Never used it till recently, battery is a bit old so sometimes the charge is a bit too low to kick the bike over (usually after sitting there for 3-4 weeks). I find that with one swift kick it starts, and then its the magic button all day.

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Super Guru

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interesting feed back , over all the electric leg is the go with the kick start waiting in the background if and its needed .

and its best to tie it back to prevent it flogging around .

from these few comments the cost of a kick start kit would be hard to justify .if you could find one .



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I kicked started mines once in 18 months.  And that was just to see if it was easy enough. had to kick start my TT500 always back in the 80s.



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Pendo wrote:

Never used it till recently, battery is a bit old so sometimes the charge is a bit too low to kick the bike over (usually after sitting there for 3-4 weeks). I find that with one swift kick it starts, and then its the magic button all day.


 What I do is I keep batteries charged by using a timer, I plug a battery charger into a power outlet timer, a digital one so every second day the charger kicks on for a couple of hours

then off again, this keeps my battery in top condition so is always ready to go, also keeps your battery from dying permanently.



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Guru

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Here's another question on starters

I assume most of us have cars so when was the last time your starter in the car failed ?

My Toyota Hilux is 14 years old, a 3.0ltr diesel and it's never failed, 365,000k, had 3 batteries I think though !

 



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When I managed to run my battery flat I bumped it.

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I never use the kick starter, too hard to start it with it, electric starter is the only way to go. I have a 1996 OE which has electric start only
and a 2005 with both and never used the kick starter. Oh and always wear boots when kick starting, saves the shins getting skinned. Learned
the hard way!!

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Very often. i like the feeling...remembers me my...dirty past(other off road bikes with kick start only),plus its an easy way to save some power for battery..

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starting to see a trend towards the electric leg . are spoilt ? biggrinbiggrin 



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ttboof wrote:

starting to see a trend towards the electric leg . are spoilt ? biggrinbiggrin 


Yep we get used to the 'button', I was out on my 1956 Matchless when it stalled - instinctively I pushed a button that wasn't there - oh dear could be heard. 



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Super Guru

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matador wrote:
ttboof wrote:

starting to see a trend towards the electric leg . are spoilt ? biggrinbiggrin 


Yep we get used to the 'button', I was out on my 1956 Matchless when it stalled - instinctively I pushed a button that wasn't there - oh dear could be heard. 


would love to have been there ,one of those moments I like to remind people of biggrinbiggrinbiggrinbiggrin 



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Kick start very light.
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I have noticed my kickstart is quite easy to push down it still starts and runs but how easy is it ment to be my old crf250 cough was very tight. 



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It is not that hard to push mine down either, but then I do have heavy feet...

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kickstart lever
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good evening,i have managed to get a kickstart conversion kit thats missing the actual lever for my ttr,a possible fit is this one i found on ebay,the item is

  191663528336. <- KLICKY LINKY

  others ive found online dont seem to have the right curves or the shaft end looks wrong,this one looks ok.has anybody tried one?.martin

 



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Kick start levers
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Yep that will fit and is about as close as you will get to the TTr one. most of the Honda xr xl 250-400-650 kickers are the same

Pug

ps and yes I have offered up one from a 1984 xr 250 and one from a cb 250rs both fitted



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RE: kickstart lever
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thanks pug/brian,ones on the way,if it fits well i will post a pic for reference,the parts were from a spares bike so not a kit as such,i won a motor[no kickstarter but+oil cooler]on ebay and am planning to rebuild it without the startermotor/mechanism over the winter,also thinking of fitting a mechanical speedo and better lighting,i have seen one on here that has a led spot under the headlight that looks ok so may copy that.all the best.martin

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Just had an XR kickstart delivered from our trade supplier and did a trial fitting. As Martyn said, it's a pretty good fit biggrin

Kickstart lever.jpg

 

So I have added it to the eShop here wink

Brian



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Super Guru

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Stopping the kickstart lever rattling
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If the kickstart lever is left to its own devices, it's constant movement will wear the ball bearing at the bottom that locates it and it will become increasingly floppy.

My simple solution is to slip a small zip tie through the bottom shock reservoir Jubilee clip and hold the kickstart lever tight against it with a band of rubber.

Kickstart retainer.jpeg



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Have done the same thing, but just with a zip tie.

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Guru

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Mine is starting to get a bit loose, caught my boot a couple of times lately as it was flopping out, a good clean, grease and reset the spring should fix it, then add the Cable Tie

OR

just be a lazy bastard and just add the cable tie :D

 

..

 



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Kickstart
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Hello from Virginia USA.  Been around for a bit but never engaged.  Looking for a kickstart kit for US 2003 TTR250.  All I've seen is that nobody can seem to find them.  Will take new or used.



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Hey Mate, If no one on here has 1 lying around try a Yamaha dealer in Australia.
Being standard gear on ours over here, I'm sure someplace would have a replacement.


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Super Guru

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I can no longer get new ones.

I have a kit here fitted to a bike that I can remove for you.

Cost would be £188 Including new pin and seal.



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Super Guru

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The official Yamaha kits were £310 about 10 years ago before they became unobtainable so that seems a very fair price Steve.

See http://ttr250.com/TTR_retrofitting_kickstart.htm for fitting instructions.

Brian



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Newbie

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I'll take it!  I'm not prepared to search three more years.  Thanks Steve!



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Super Guru

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Ok Great

Will strip it out of the bike and weigh for postage tomorrow.

Please pm me your email.

Steve

 



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Jealous....

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devon_rich wrote:

Jealous....


 Maybe I should look into ripping them out of busted ttrs here in Oz for you guys? I've used my kick start twice in 12 months and just for giggles. Don't really get the fascination with them. Keep a battery tender on and check your battery maybe? Never really cared that I have it tbh. Never use the kick on the trails Etc. Why do you all seem to like them so much?



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Super Guru

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Agree mine's cable tied to the frame only used it twice it's awkward and only turns the motor fairly slow 

Only thing on the ttr that's not up to par 

But might be handy if the electric leg fails 



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Never actally needed one. But not having one makes me nervous about dropping the bike in water. Have dried a few bikes out and then needed jump lead's to restart. Carry a length of flex just in case.

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Super Guru

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Used mine Saturday, when I drained the battery.

Would not be without it, electric / kickstart / 6 Gears / Air cooled = The ultimate trail bikesmilesmilesmile



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It's pretty easy to push start a 250 though. How bout you fly to Oz, take my assembly for naught and put a plug in, seal it up and we'd both be happy. Nice place for a visit/holiday here :)

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Looking for somewhere to ride on my 50th, may take you up on the offer Chris!



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Super Guru

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Although Yamaha no longer sell a kickstart kit as such, it is still possible to buy the individual parts. 

I took time out from the workshop to do some investigating. It took a while as there are 22 parts involved but UK retail price including VAT for the whole assembly would be £675.01 dohevileyebleh

Most of the parts are not in stock and would have to be back ordered so it might take a while no

Brian



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