58 replies to this topic

[s14 2510s TT Silver Member]

• best fitting is the yz426 lever. yes you use the yz426 knuckle and lever.

[BRM TT Addict]

s14 2510s, on 23 February 2012 - 01:31 PM, said:

• best fitting is the yz426 lever. yes you use the yz426 knuckle and lever.

Photo of it fitted please

[s14 2510s TT Silver Member]

The top end is off my bike now. As soon as I get it back later tonight hopefully ill take pictures. The 426 kicker fits oversized tanks the best.

[Pincushion TT Addict]

Thanks! Good info.

[s14 2510s TT Silver Member]

Im begining to have soo many spare parts I could put another bike together with them.......
I worked on it today some but the beers calling so im going to finish it saterday.

[BRM TT Addict]

s14 2510s, on 24 February 2012 - 04:45 PM, said:

Im begining to have soo many spare parts I could put another bike together with them.......
I worked on it today some but the beers calling so im going to finish it saterday.

It is Saturday already.........here anyway

[BDubb106 TT Addict]

s14 2510s, on 24 February 2012 - 04:45 PM, said:

Im begining to have soo many spare parts I could put another bike together with them.......
I worked on it today some but the beers calling so im going to finish it saterday.

You could always send some my way lol

[s14 2510s TT Silver Member]

I did make my dad a steel frame out of my spare parts last year. It kinda my spare 250 too for when mines down. Im hard on stuff and dont want to have to be the guy broken down while my buddys are riding.

[BRM TT Addict]

s14 2510s, on 24 February 2012 - 04:45 PM, said:

Im begining to have soo many spare parts I could put another bike together with them.......
I worked on it today some but the beers calling so im going to finish it saterday.

It is nearly Saturday ........ again. Photo please

[Pincushion TT Addict]

Post it up. I want to see too

I scored a 1999 kickshaft on ebay and brought everything to RB for machining. Everything looks great and all the gouging from the breakage was machined out and the 1999 seal fits right in.
I've got about $60 invested in this project so far vs $209 the dealer wants for an OEM 2006 kickshaft. I still need a kickstarter, but I should come in way under budget and have a permanent fix (I sure hope so....)


Anyone recommend a kickstarter that works well with both an 2006 OEM and IMS 3.2gl tanks?


few pics....

[shrubitup brap]

Pincushion, on 01 March 2012 - 06:18 PM, said:

Anyone recommend a kickstarter that works well with both an 2006 OEM and IMS 3.2gl tanks?

This is an easier task than trying to make the OEM kicker fit the Clarke tank. Bad clearance on that one such that it wears a hole in tank eventually.

[Pincushion TT Addict]

How about pictures of the kickstarters mounted? I'm done with my rebuild and now only need the kickstarter, but I still dont know which fits best and/or feels similar to stock while kicking.
If anyone has done this mod and can post pics then please do. Also, dont forget to mention what year and bike the kicker came from.

[WR250_YZ250 TT Newbie]

WR250_YZ250, on 21 February 2012 - 05:49 PM, said:

I'm ready to pull the trigger on replacing the 2002 parts on my bike with 2001.
I only had one concern. Is the spring end of the kick axle the same size/diameter on both the 2001 and 2002?
I note that on that end of the shaft, the torsion spring is the same part number, but the Spring Guide is different.

If this end of the axle is the same diameter, then I believe the parts required would be:

2001 Kick Axle Assy 5CU-15601-01-00
2001 Cover, Crankcase #3 5CU-15431-00-00
2001 Oil Seal 93102-20484-00
2001 Kick Crank Assy 4EW-15620-02-00
All other parts from the 2002 should work except for the bolt and washer to attatch the kick cran assy.

I hope to have my hands on a 2001 Kick Axle Assy by the end of the week, so I can measure the diameters.

I finally got around to finishing this. The 2001 parts worked perfectly. Bought a used 2001 kick axle, a used 2001 clutch side cover, a used 2001 kick lever assembly, a new cover gasket, a new water pump cover gasket, and the bolt and washer for the 2001 kick lever assembly. The 2001 kick lever is a little shorter than the 2002, but it fits fine, and tucks up out of the way. Went together with no problems. Now we will see how long it lasts.
There was another post recomending machining the 2002 case to fit the 20 mm kick axle seal, and I see no reason that this would not work. Depends on how much it would cost to buy a used cover versus how much to do the machining. I only paid $50 for the complete cover, so there is not a lot of money to spend for machining.
Thanks to all of the early posters who got me going in the right direction. My son had broken 2 kick axles, and I was ready to deep 6 this sucker. This was a simple fix, and saved me the expense of starting over on making a YZ 250 into a trail machine.

Edited by WR250_YZ250, 11 May 2012 - 06:57 AM.

[Pincushion TT Addict]

Good info. It never occurred to me to expand my search for 01 and older YZ250 kickers.

I finally manned up and bought a 2000 yz426 kicker off ebay. It should be here this week and I'll post up pics.

[espkul TT Member]

I've ridden an yz250 which was modified. Something had been done to the cylinder (same thing which was done to the cr500's, don't know what) which made it as easy as an 125 to start.
Why haven't anyone suggested this mod?

[shrubitup brap]

espkul, on 14 May 2012 - 08:35 AM, said:

I've ridden an yz250 which was modified. Something had been done to the cylinder (same thing which was done to the cr500's, don't know what) which made it as easy as an 125 to start. Why haven't anyone suggested this mod?

What is a compression release?

[espkul TT Member]

Strange no one has mention it... Will the perfomance be affected by this "groove" or what it is done to the cylinder

[CaptDan TT Titanium Member]

There was a thread on adapting a compression release to the YZ many years ago (probably long-gone by now), but yeah, people had been looking into it.

[Pincushion TT Addict]

It works. The 2000 yz426 kickstarter hits a clutch cover bolt when pushing the kickstarter into its recess, but rotating it back a 1/4" allows enough clearance to close it relatively easily. I'll grind the kickstart lever for more clearance later on.

It feels great when kicking it over. It's beefier than the stock 06' starter and feels natural to kick.
I'm stoked! Cost me about $100 when all is said and done.

Here's what I used:
1999 yz250 kickstart gear/shaft assembly
2000 yz426 kickstarter/knuckle
2006 yz250 side case cover machined for 20mm shaft
1999 yz250 oil seal. Fits into 2006 case cover with no machining