sms lån

Retrofitting a kickstart to a Yamaha TTR250

The blue TTRs in the UK are all dual start with electric and kick starters. Some of the white TTRs came with a kickstart fitted, presumably an optional extra when new or a kickstart kit (expensive!) fitted in later life.

However, all non-kickstart TTRs all have the machinings and provision to retrofit a kickstart.

There are quite a few TTRs now being broken for spares and it is possible to obtain the kickstart mechanism from one of these and retrofit it. Easy to do and takes about 90 minutes. These are the parts you need:



As usual when going inside the engine it is essential that you have the workshop manual to hand for full details of the procedures, torque settings, etc.

This pictorial guide is just to help you along the way. The work was done on my brother Trev's white Open Enduro using second-hand kickstart mechanism from a TTR engine I had broken for spare parts.

Tools needed:- a socket set, torque wrench and hex-sockets.

Parts/supplies: second-hand kickstart mechanism plus kickstart spring retaining pin (part number 55V1566800) and new oil seal (part number 93102-17263 size 25x17x4) plus maybe a new clutch cover gasket on standby just in case the original gets damaged.

Before you start, make sure that the petrol tap is turned off and the petrol cap doesn't leak, Otherwise just remove the petrol tank. Lean the TTR over onto a firm surface such as a bike stand or wooden box and make sure it is secured safely. It should then be comfortable to work on the clutch side of the engine where the kickstart will be fitted.

Make sure the floor and working area is clean. I tend to rob the recycling bin of old newspapers and lay them around to give a clean absorbent surface on which to put down any parts removed. You are definitely going to lose a little oil.

First step is to remove the brake pedal and footpeg to make access easier. Then loosen the exhaust system to allow access to remove the oil feed banjo bolt at the top of the casing. Remove the casing bolts and keep them safely in order as they come out as they are different lengths. Remove the cover carefully to keep its gasket intact.

Remove the clutch basket.

You can now start to fit the kickstart mechanism starting with the intermediate gear that links the kickstart with the clutch.

Fit the stop plate as shown above.

The kickstart mechanism pops right in.

Now fit the small steel splined shaft that retains the kickstart spring. DON'T KNOCK IT ALL THE WAY IN! See below:

It must protrude about 7mm above the side of the crankcase as shown above.

Refit the clutch.

The original casing has a blanking plug where the kickstart shaft will go through so knock it out.

Clean the orifice, oil the seal and pop it in.

Grease the kickstart shaft to help ease on the cover and protect the seal lips.

Your engine should start to look like this.

Fit the kickstart itself lining it up as above. Refit the brake pedal, footpeg and exhaust system.

Get your TTR upright and check it all works. Ours did and the TTR started second kick ;-)

Job done!

Brian Sussex