Fix your Yamaha AT-1 CT-1 kickstarter

DIY repair of the AT1,AT2, AT3, CT1, CT2, CT3, DT125 Kickstarter. The problem exists that the kick shaft starts eatting into the case and will at some point stick or cause more damage. This video addresses the root cause and shows how to repair. These are getting hard to find and because of this, more will need to be repaired in the future. I use a hydraulic press, lathe, and a TIG welder to accomplish this proceedure.

[@eelnoizpanx]

This video works for the LT 2 and 3 100. Thanks. I watched all the way to the end to find out I'm not wrapping the spring around enough.

[@montana2strokeracer]

Hey that's great, it could be the kick shaft slipping too, so if the problem returns that will be the issue. Good luck.

[@jezzeestewart3712]

Thank you for all your help. I’m trying to assemble my CT one I have painted everything and now I’m trying to get her together and to get her running. Took me a long time to remove rust and paint everything properly. Still mini parts need help but you have helped with some of these videos with a brief idea of assembly. Thank you.

[@montana2strokeracer]

Hi, yes, the cleaning is the hardest part, not to mention, dirtiest. It does take a lot of time, but the better you do it the better the job will turn out. Just hang in there and get it done and you will be super happy with the results. Thanks for hanging out in the shop with me.

[@jezzeestewart3712]

@@montana2strokeracer for sure you do killer work too are you in California?

[@montana2strokeracer]

I'm in Montana

[@pervaizakhtar2602]

I appreciate your greatest effort. I am really admir your knowledge. You are great than me.

[@montana2strokeracer]

Thank you, sir. I am having a good time making these videos. My hope is they will help some folks.

[@LarryJohnson-tc7xc]

I'm first today, what's happening Dale, this is a very important topic. Otherwise we're push starting our vintage motorcycles, not cool 😎.

[@montana2strokeracer]

Nice to see you got here before Frank. Yes there is more repairing these days than parts replacing. It will get worse Im sure. Parts are getting harder to find. Thanks for watchin

[@retromechanicalengineer]

This was a good one Dale. We are definitely seeing a reduction in the quantity of good used or new old-stock parts available for our older machines. Coupled with the high prices demanded for (often sub-standard) aftermarket parts, it means that we as restorers will have to find new ways to reclaim worn or damaged items. This was a perfect example and very well presented. Best wishes, Dean.

[@montana2strokeracer]

Thanks Dean, well said my friend, it is fun, but at the same time frustrating, what we have do to save parts. Most of the folks out there dont realize what you have to go through in time, talent, and machinery, to pull it off, and then bock at the price. Thanks brother

[@cainbeeping8480]

The lath saves the day again.

[@montana2strokeracer]

Yes sir, every time.

[@jamesws3]

Great repair! Learned a lot. Doubt that will ever move again!

[@montana2strokeracer]

Thanks Jim, I hope its fixed for good, course I know what causes it, so I will treat it nice.

[@markaddy53]

great job again dale il bear this in mind doing a dt 175 mx engine 4 someone sure thayl av the same issue

[@montana2strokeracer]

Hi Mark, not sure if the DT 175MX is built the same or not. But now you have something to compare it to. Thanks for watchin.

[@iidocumar7962]

Thanks Papa

[@frankdillon6127]

carry on,im here!

[@montana2strokeracer]

Wow Frank, thought I was going to have to call out the National Guard. Glad to see you made it. Thanks for following along.

[@frankdillon6127]

Dale did you ever notice the right side foot peg on a 1974 Kawasaki H2 needs to be lifted up before you depress the kick starter. Okay im a trivia nut!!

[@montana2strokeracer]

I think I did know that, it has been along time since I had to start one of those, probably forgot more than I know at this stage of the game. Time marches on.

[@frankdillon6127]

@@montana2strokeracer does the word Dinosaur, discribe us? last of a dieing breed . all the young people that restore and love the old machines cant replace the feelings that us old guys have because we lived during those days. kind of like reading about history and actually living it.

[@michaelpeterson8954]

Dale, I am working on a 1969 Yamaha AT1 I had the same issue with the kick shaft tab getting into the casing just slightly. NOS shaft is on its way, which is the newer style in your video. First question is my spring upon disassembly was wrapped from static position to the kick spring stopper. If I try to wrap the spring one entire revolution it seems and looks way too tight. Which is correct? Second question my kickstart assembly is assembled correct per the diagram, however the kick clip sometimes does not return to its correct position in the casing. What would cause this? This was with the old kick shaft which is early style as the one you fixed in this video.

[@montana2strokeracer]

Hey Michael, thanks for stopping by the channel, the spring only gets wrapped about a half turn. If the shaft has slipped, then it looks like it has to be wrapped more. Not sure what the issue is with the clip, I think you're talking about the little spring that fits in the pocket. How is the in and out play when the side cover is on? If you have a lot of play there, that could cause it. I have to make shims to go between the shaft and the case to limit that play. The older parts manuals specify the size and quantity of those shims as required. Don't think the online parts manuals show them at all.

[@davidboyte4340]

Great repair video Dale thanks for sharing. Had a non related question to this repair but im curious what paint you used for side casings on the engine I know you said what it was in another video but I can’t seem to find it. Want to get my CT3 as close to original as possible thanks for all these great videos. Dave

[@montana2strokeracer]

Hi David, Im not sure the paint I use is the so called correct color, most of the guys on the Yamaha forums say to use DE 1615 Dup-li-color. Its a bit shiny to me. So I tone it down a bit...I use Rust-oleum 7716 heat resistant silver, then coat that with Rust-oleum Clear. When you put the clear on it turns it kinda grey. You can try both if you want and decide for your self what pleases you. Hey thanks for following the channel.

[@frankdillon6127]

so you determined that letting the lever slam up after starting caused the issue. seems like a unique issue to this model of Yamaha?

[@montana2strokeracer]

Yes its pretty common on these bikes, never tried to fix it before. Parts are getting harder to get and more expensive.

[@manuelmendoza7882]

Do you fix quads? 125 Yamaha breeze transmission

[@montana2strokeracer]

Hi Manuel, I have never worked on a quad, bet they are similar to the bikes. I really just work on the old dirt bikes. There were no quads when these bikes were new. The closes would have been three wheelers.

[@cainbeeping8480]

Second

[@montana2strokeracer]

Wow Frank is really slipping to let all you guys in ahead of him. Nice to see ya here Cain.