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The TTR250 FAQ web pages -> TTR250 -> Repairs and maintenance -> Kick starter information
Post Info TOPIC: Kick starter information
ttr steve


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RE: Kickstart
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Good work Sherlockbiggrinbiggrin

Crazy moneyno

Mind you if someone was that desperate, I would be willing to order it in for them.



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TTRfan


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Kick starter information
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Lots of information and photos about the kickstart mechanism here. It has been updated with extra information from this thread in an addendum at the bottom of the page wink

As usual, please let me know of errors or omissions!

Brian

 



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One1


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Kickstart
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any chance my spare 125 engine kickstart is transferrable to my 250? I have a 125 ttr thats used for parts and it has a complete engine with a bad top end. I was thinking of drilling the side plate and adding the kick start if the parts were the same as in the 250. I havent seen a 250 kick start so idk if they are the same parts. 



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petenz


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Do yer really feel that lucky....
i would say not a chance in hell.




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TTRfan


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Kick starter information
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Many have tried to find an alternative kickstart that will fit the TTR - and many have failed!

If you succeed please please let us know.

Good luck!

Brian



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ttr steve


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I have looked at many Yamaha kickers and none are the same as our bikescry

The holy grail for sure! ( no blasphemy intended )wink I will keep looking!



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One1


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Retrofit kickstart
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i have a spare ttr-125 block with a kick start and it looks very similar to the one in the faq. No idea if itll fit, even if i have to mod it a little i would. Anyone ever compared the two?



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TTRfan


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No-one was able to answer when you asked earlier so my guess is that you might be our guinea pig wink

Brian



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ttr steve


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Hi I have found this fische of a TT-R125

TT-R125 kick start.png

Nothing like the TTR250 kicker

ttr250 kicker.png

Hope that helps

Steve



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TTRfan


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I had a very worn swivel bolt on my spare kickstart lever so ordered a new one from Fowlers - it's described as "SCREW CROSS RECESS" and has part number 9015106005.

I am very disappointed in the screw they sent and don't think it is fit for purpose.

Aesthetically, the new screw is bright finished whereas the original part would have been "drab olive green". Also, the head is flat rather than domed.

But, I think the real problem is that it is threaded along its whole length whereas the original had a plain shaft that sat in the retaining groove as you can see in the photo. I am sure that the threaded portion of the new screw that sits in the groove will wear very quickly.

Swivel bolt.jpg  Kickstart ball bearing and spring 4.JPG



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mossproof


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Agreed Brian - the thread will wear much faster. Only solution I would try is to get a much longer countersunk head bolt (ideally "raised countersunk pozi screw") which will have some unthreaded shank section which you could then run a die down to the desired thread length.
I think finding an olive drab green one might be a fruitless task, but with your home plating kit nothing should stop you



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TTRfan


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Many thanks for giving me the technical terminioogy to use Simon!

My Googling for a "6mm raised countersunk pozi machine screw" has failed cry

Not sure how to proceed. Do I need someone with a lathe to turn down a bigger diameter screw perhaps? confuse

This is what I am looking for but, as Simon suggests, I could work with a longer screw as long as it has at least 14mm of plain shank.

Kickstart screw 2.jpg



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TTRfan


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I asked for help on the Classic  Motorcycle Workshop Group on Facebook and despite a huge response, I have drawn a blank. One thing that did come out of it that the head is almost certainly JIS not Pozi - I read an interesting article on the difference here. The fact that it's a Japanese bike also points to JIS. 

Ah well......

Brian

PS There are quite a few of the correct shaped bolts available in the US but the postage costs are silly high. See here. I guess with Covid travel restrictions there won't be anyone travelling back to the UK could carry one over for me cry 



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mossproof


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Agreed probably JIS, but I imagine you'll have even fewer hits searching for that!

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TTRfan


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Agreed Simon. The closest found so far is Pozidriv - see here.



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