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TW200 Performance and Customization

Started by tsfarling at 11-25-2008 10:43 AM. Topic has 31 replies.

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   11-25-2008, 10:43 AM
tsfarling is not online. Last active: 5/27/2010 3:37:41 PM tsfarling



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2008 TW200 kick start
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I had my kick start installed earlier this week on my 08 tw.  Works perfect, great addition!  They should have never taken them off.  After install and parts it came to $314.  Highly recommend.

2008 TW200, Jimbo's Cafe Shield, Front and Rear racks
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   11-25-2008, 12:17 PM
Imaposer is not online. Last active: 11/3/2009 5:03:56 AM Imaposer

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Re: 2008 TW200 kick start
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Did you source the parts yourself, or did you just take it the dealer and tell them you wanted a kick start installed?

I’ve seen a thread here about using the XT225 kick start kit and the lever from older model TWs but I’m just wondering what route you took.  Do you have the parts list and a breakdown of the costs as far as parts vs. labor?  I would prefer having the backup myself and plan to add the kick start myself so I’m just trying to track down the best way to go about getting the required parts.


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   11-25-2008, 12:32 PM
Two Shoes is not online. Last active: 7/5/2010 9:47:48 PM Two Shoes



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Re: 2008 TW200 kick start
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 Imaposer wrote:

Did you source the parts yourself, or did you just take it the dealer and tell them you wanted a kick start installed?

I’ve seen a thread here about using the XT225 kick start kit and the lever from older model TWs but I’m just wondering what route you took.  Do you have the parts list and a breakdown of the costs as far as parts vs. labor?  I would prefer having the backup myself and plan to add the kick start myself so I’m just trying to track down the best way to go about getting the required parts.

 

Ditto!


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   11-25-2008, 1:19 PM
Two Shoes is not online. Last active: 7/5/2010 9:47:48 PM Two Shoes



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Re: 2008 TW200 kick start
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This is a copy of the parts list for the kick star asy from Ron Ayers.

Ref # Part # Description Qty Required Spec #
Notes
1
KICK AXLE ASY
1
2
CLIP
1
3
COVER,SPRING
1
4
SPACER
1
5
SPRING,TORSION
1
6
CIRCLIP
1
7
WASHER,SPEC'L SHAP
1
8
GEAR,KICK
1
9
WASHER,PLATE
1
10
OIL SEAL,SD-TYPE
1
11
WASHER,PLATE
1
12
GEAR,KICK IDLE
1
13
WASHER,CLAW
1
14
CIRCLIP
2
15
KICK CRANK ASSY
1
16
BOSS,KICK CRANK
1
17
SPRING,COMPRESSION
1
18
BALL 7/32
1
19
SCREW,COUNTERSUNK
1
20
PLUG,SPEC'L SHAPE
1
21
BOLT,HEXAGON
1
22
GEAR,IDLER 1
1
23
SHAFT 1
1
24
GEAR,IDLER 2
1
25
WASHER,PLATE
1
26
STR CLUTCH OTR ASY
1
27
SPRING,COMPRESSION
3
28
CAP,STR CLUTCH SPR
3
29
PIN,DOWEL
3
30
BOLT
3

Subtotal $353.88

I'm not sure what would be needed and what we already have in our bikes but that total is with every part from that list in the proper qty.


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   11-25-2008, 11:06 PM
tsfarling is not online. Last active: 5/27/2010 3:37:41 PM tsfarling



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Re: 2008 TW200 kick start
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Im sure I could get it all from the dealer but I'm sure it looks like the one above.  My copy just had kick start kit on it and the labor price.  They said it was from the XT kit.  I guess they are similar.  He had to inch the kick out a bit at the end to clear the brake but it looks and works great.  If you want I can ask them for a break down in the parts.

2008 TW200, Jimbo's Cafe Shield, Front and Rear racks
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   11-26-2008, 4:52 AM
Imaposer is not online. Last active: 11/3/2009 5:03:56 AM Imaposer

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Re: 2008 TW200 kick start
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Nah, that’s ok, but thanks anyway.  There are already a few threads on this subject.  I’ve seen individual parts lists like the one two shoes posted and I’ve seen the deal about using the XT225 “kit”.  It seems that Yamaha makes a “kit” that already includes all the required parts for a lower price than ordering the parts individually.  It’s specifically for the XT225 but also works on the TW except for the lever itself.  The lever is included in the “kit” but since it is for the XT it has a different shape and interferes with other parts.  But, you can get a lever for the older TWs and everything works as it should, or do something to modify the XT lever so that it will work.  Looks like you have a dealer that actually knows what he’s doing. Yes [Y]


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   11-26-2008, 10:17 AM
QWERTY is not online. Last active: 1/27/2010 11:44:02 AM QWERTY

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Re: 2008 TW200 kick start
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The XT225 kickstart kit is available from stadiumyamaha.com for under $130.
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   11-27-2008, 7:37 AM
tsfarling is not online. Last active: 5/27/2010 3:37:41 PM tsfarling



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Re: 2008 TW200 kick start
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i think the parts were almost 200 from where they got them from but then i had to pay for labor, i dont have the space or time to install it so it cost me some money, oh well, its on and a huge addition.

2008 TW200, Jimbo's Cafe Shield, Front and Rear racks
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   12-16-2008, 8:50 AM
jgrono is not online. Last active: 2/17/2009 12:29:04 AM jgrono

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Re: 2008 TW200 kick start
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I just finished the install, parts cost me a few dollars over $200. I videotaped the whole thing, pictures of parts and part numbers are included. The job wasn't bad at all. here's a link:

http://www.youtube.com/profile?user=jgrono&view=playlists

Jim

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   12-16-2008, 11:11 AM
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Re: 2008 TW200 kick start
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Thats a great video, makes it all the more clear in your mind before you start a project like this.

Thanks.


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   12-16-2008, 1:01 PM
Igofar is not online. Last active: 6/20/2010 2:21:39 AM Igofar

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Re: 2008 TW200 kick start
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Thanks for posting the parts list and the youtube video.
My only suggestion would be to read the shop manual first, stop prying on soft alloy cases, use the proper tools, snap ring plyers, sockets, impact wrench etc.
The side case is held in place with a couple collar spacers.  You can get the side case off much easier by GENTLY tapping it straight on, thus causing the side case to bounce free.  I'm surprized your bike does not leak where you pried with the screwdriver :(
Also it appeared the first few attempts to remove the clutch nut, you were trying to force it in the wrong direction! Good thing that didn't strip.  Again read the service manual or ask someone.
Glad it worked for you.

Just sayin'


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   12-16-2008, 4:29 PM
amolaver is not online. Last active: 10/24/2008 1:52:30 AM amolaver

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Smile [:)] Re: 2008 TW200 kick start
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the videos are fantastic - thanks for taking the time to record and post 'em!!!

a pair of snap-ring pliers will make it less likely you'll stab yourself :) DAMHIK
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   12-17-2008, 1:24 AM
Two Shoes is not online. Last active: 7/5/2010 9:47:48 PM Two Shoes



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Re: 2008 TW200 kick start
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 jgrono wrote:
I just finished the install, parts cost me a few dollars over $200. I videotaped the whole thing, pictures of parts and part numbers are included. The job wasn't bad at all. here's a link:

http://www.youtube.com/profile?user=jgrono&view=playlists

Jim

Great work! And welcome!


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   12-18-2008, 5:59 AM
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Re: 2008 TW200 kick start
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J, I think your video will help folks feel more confident when it comes time to install a kick starter on their TW. It took me awhile to find the flats on the side case to tap on too. I will also plead guilty not reading the manual thoroughly before a project, and sometimes it makes for wasted time and a re-do. I am 60 and bought my first set of snap-ring pliers 15 years ago. A real good tool to have. Thanks for a project well done. Gerry
Be safe my Friend.
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   12-18-2008, 10:07 AM
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Re: 2008 TW200 kick start
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 tsfarling wrote:
i think the parts were almost 200 from where they got them from but then i had to pay for labor, i dont have the space or time to install it so it cost me some money, oh well, its on and a huge addition.

that cycle is worth more now with that thing on there. almost 125% reliable.


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   12-19-2008, 4:17 PM
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Re: 2008 TW200 kick start
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I just ordered the Yamaha kick start kit from Bikebandit.  $109.  (minus the correct kick start lever).  Anyone mod the XT lever to work?  What exactly doesn't fit with the XT lever? 

Hodakaguy

08 TW200 - Adventurized!
10 KTM530EXC - Orange Baby!
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   12-19-2008, 7:57 PM
QWERTY is not online. Last active: 1/27/2010 11:44:02 AM QWERTY

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Re: 2008 TW200 kick start
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The XT lever can be modded but it is supposedly not easy to do. the consesus seems to be an eBay TW lever is worth the money.
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   12-20-2008, 10:25 PM
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Re: 2008 TW200 kick start
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I had to push start last night. It was just too damn cold to crank. Crying [:'(]
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   12-22-2008, 1:16 PM
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Re: 2008 TW200 kick start
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New battery time maybe? Mine has cranked almost 20 degrees below zero, although not by much.
2007 TW200 - 130# main, 15T front sprocket
1995 EX500 - for sale...?
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   12-22-2008, 7:07 PM
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Re: 2008 TW200 kick start
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Great thread! After the first of the year I'm going to do this mod to both of my TW's, we do 20% off-road riding but have some longer off-road excursions planned for next year and this is the sort of mod which could really help if (/when) one of us leaves a key on in the middle of nowhere.

--Kevin

'03 TW200 - Odyssey battery, IMS Super Stock pegs.

'03 TW200 - Odyssey battery, IMS Pegs, FMF Exhaust
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   12-24-2008, 4:31 AM
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Re: 2008 TW200 kick start
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The dealership in Glenwood Springs CO gave me an estimate of $440 parts & labor to install the kickstart. They said I would have to buy a side cover gasket as one was not included in the parts. I can't tell from the bike-bandit print-out.
They did not mention the correct kickstarter lever.
I'd love to give them some work, but not that much. I guess I'll just do it myself.
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   02-16-2009, 8:41 AM
jgrono is not online. Last active: 2/17/2009 12:29:04 AM jgrono

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Re: 2008 TW200 kick start
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Your welcome to everybody that found this useful.

As for the shop manual, there are some errors in it, especially the locations of some of the parts for the kick starter. Check the comments on the video and eventually I will post the solution up there after I verify with another guy who is working the noise problem. I ended up throwing those diagrams to the side after the first two errors. I fixed it but don't remember what my final setup was.

As for my attempts at the crankcase, yeah it was pretty crappy, but that's why it took me so long, I was trying to be nice to the gasket mating surfaces, but the corrosion on the pins wouldn't let me and I finally gave into the screwdriver and hammer. I should have tried it earlier and it would have saved me uploading a video or 2. There are a couple places on the crankcase cover that extrude out and are not mating surfaces, they're tricky to find, but you can tap there without fear of damage.

And the clutch nut, yeah that was funny, my buddy wanted me to upload the whole thing unedited so he could see the whole process, swearing and all. My favorite part is where I dropped the tool in the oil pan.....

When anybody else did this on an older tw did they find white stuff on the bolts? I thought it was corrosion, but it seemed to be on most of the bolts almost neatly. Is it white threadlocker that yamaha uses?

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   02-16-2009, 8:44 AM
jgrono is not online. Last active: 2/17/2009 12:29:04 AM jgrono

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Re: 2008 TW200 kick start
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Yeah snap ring pliers.......that would have been really nice!

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   02-16-2009, 6:52 PM
donniedarko is not online. Last active: 7/6/2009 1:06:38 AM donniedarko

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Re: 2008 TW200 kick start
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Jgrono, one vid they barred bc of music I think...
Thanks for posting.

By the way the noise at the end, get that fixed whats up?
thanks


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   03-01-2009, 12:53 AM
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Re: 2008 TW200 kick start
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<BLOCKQUOTE><table width="85%"><tr><td class="txt4"><img src="/Themes/default/images/icon-quote.gif">&nbsp;<strong>Hodakaguy wrote:</strong></td></tr><tr><td class="quoteTable"><table width="100%"><tr><td width="100%" valign="top" class="txt4">I just ordered the Yamaha kick start kit from Bikebandit.  $109.  (minus the correct kick start lever).  Anyone mod the XT lever to work?  What exactly doesn't fit with the XT lever?  <br><br>Hodakaguy<br></td></tr></table></td></tr></table></BLOCKQUOTE>

i'm going around in circles at stadiumyamaha and bikebandit trying to find the xt225 and/or tw200 kick start kit. is there any further information you guys could supply that would shorten the search?
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