Author Topic: DT230 Kick Start  (Read 924 times)

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Offline kiwidirtrider

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DT230 Kick Start
« on: February 01, 2018, 02:29:03 PM »
Hello All ,Can someone tell me where I can get a DT230 kick start kit from please? Thanks.
IT200S,DT200R,DT230,DT175FX2,DT125F,DT100F,DT175S,TT350,BW350,AG175X7,AG100B,CHAPPYX4,50TH ANIV YZ450,60TH ANVIV WR450,BW100.

Offline Durmatti

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Re: DT230 Kick Start
« Reply #1 on: February 05, 2018, 06:55:39 AM »
Hi Mate,

Unfortunately you're not likely to find an original kit, but the good news is you can use all the bits from a DT125R kick-starter. There was a great forum post with a guide a couple years ago but it's been taken down, so I'll try and give a rundown for anyone who wants to try it.

The DT 125 bits you need are the kickstart mechanism, lever + Nut, and Idle gear. Usually easy to get from a breaker and probably the same as some other models - but do your research there. You will also need a clutch lock washer, a clutch cover oil seal (DT125R one is the right size) and a couple of circlips and washers for the idle gear. Best to get those bits new from Yamaha as they're quite cheap or should be replaced anyway.

You need to take off the clutch basket as the idle gear shaft is behind it. This will take either a rattle gun or a good clutch holder, but be careful as the basket is quite brittle. Once that's off its a fairly obvious shaft with two grooves cut in it so you place the bits on: circlip, washer, idle gear, washer, circlip. This may not make sense without having the gear in front of you; but the 'indented' side of the gear points outward. Then stick the basket back on as it came off. Good practice to use a new lock washer and the clutch basket nut wants to be tightened to 90nm.

Installing the mechanism is quite simple, just slot it in and wind the spring into its seat. Pop the blanking cap out of the clutch cover and fit the new oil seal in it's place.

The lever itself is a little chunky for the space but works great with a couple of touches. I had to cut part of the silver frame guard to allow it full downwards swing - though it looks like that will be in the way of any kick lever and you can always take it off instead. The rear brake light switch is another slight complication as the DT230 has a thin straight wire connecting it to the brake lever, which sometimes gets pinched when you kick it. The DT 125's have a thicker, rigid wire that bends around the kick-start shaft and stays out of they way so if you can get one while you're sourcing the kick-start bits it saves a fair bit of hassle.

I think that' the gist of it, let me know if you have any questions or need a hand with any part numbers!

-Matt

Offline kiwidirtrider

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Re: DT230 Kick Start
« Reply #2 on: February 05, 2018, 02:07:25 PM »
Thanks for the info Matt very helpful,looks like I've got some digging around on line to do.
IT200S,DT200R,DT230,DT175FX2,DT125F,DT100F,DT175S,TT350,BW350,AG175X7,AG100B,CHAPPYX4,50TH ANIV YZ450,60TH ANVIV WR450,BW100.

Offline mikeyvet

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Re: DT230 Kick Start
« Reply #3 on: February 05, 2018, 03:02:55 PM »
I guess you already know that the DT125R and DT200R are pretty similar, maybe you could spend an entertaining arvo swapping parts out of your 200 into your 230.

Offline kiwidirtrider

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Re: DT230 Kick Start
« Reply #4 on: February 05, 2018, 07:05:42 PM »
If you have a look at my dt 200 I think you'll agree that I don't want to do that,i'm still having to much fun on it.bikepics agman.also have an it200 with a yellow frame under kiwidirtrider.I think I have a yellow fettish going on...but the 230 is safe.
IT200S,DT200R,DT230,DT175FX2,DT125F,DT100F,DT175S,TT350,BW350,AG175X7,AG100B,CHAPPYX4,50TH ANIV YZ450,60TH ANVIV WR450,BW100.