Required Tools and Parts:
- Basic tools (wrenches, sockets, screwdrivers, etc.)
- Yamaha TW200 workshop manual
- Kick start assembly (kick start lever, shaft, gears, etc.)
- Gasket set
- Engine oil and filter (for oil change after disassembly)
Procedure:
1. Preparation:
- Disconnect the battery and drain the engine oil.
2. Disassembly:
- Remove the motorcycle's right-side engine cover by unscrewing the bolts. Be careful to catch any falling components like springs.
- Remove the electric starter assembly, including the starter motor, solenoid, and any related hardware.
3. Installing the Kick Start Assembly:
- Align and install the kick start lever, making sure it engages properly with the engine's gears.
- Replace the kick start shaft, gears, and related components, following the workshop manual instructions.
- Apply a thin coat of sealant to the gasket surface before installing a new gasket and the engine cover.
4. Adjustment:
- Adjust the tension of the kick start spring and the engagement mechanism so that the kick start engages smoothly.
5. Refill Engine Oil:
- Install the oil filter and refill the engine with the recommended oil type and quantity.
6. Reconnect Battery:
- Reconnect the battery's positive and negative terminals.
7. Testing:
- Attempt to kick start the motorcycle to ensure that the mechanism is working properly.
Additional Considerations:
- Some versions of the TW200 may require modifications to the engine case to accommodate the kick start assembly. It's essential to follow the workshop manual specific to your motorcycle's model and year.
- While converting to a kick start is possible, it typically results in the removal of the electric starter, compromising the convenience of push-button starting.
Undertaking such modification without a thorough understanding of your specific motorcycle model's engine layout and wiring configuration may be riskier. If you are not confident in your mechanical abilities, it's recommended to consult with a professional motorcycle mechanic to conduct the modification process.
