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Ty80 Rear Brake Questions


dr nick
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I`m just going over a TY80 that I got for my kids to learn trials and have a couple of questions about some of the things of how they work.

The first thing I want to know about is the rear brake pedal. Its seems to either be hitting the engine casing when not being used, or hitting the small angled bar that comes off the frame when trying to use the brake. There isnt a lot of room for travel, so whats the angled bar for ???? Whats its purpose ??

The other thing I want to know about is how the rear brake set up is meant to be, The way its set up is, having the thin rod connecting from the back of the brake pedal to the actuating lever on the rear wheel over the top of the spindle. When its set up like this though, when the swing arm moves up(rear shocks compressed) the brake comes on....surely this cant be right. Is the setup supposed to go under the spindle, which seems unlikely due to the capability of being damaged. If I try and alter the nut on the rod, to slacken it off a bit, I have problems with the angled bar in my first question .

I hope you can understand what I`m getting at

Any help greatly received

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I 'think' I know which angled bar you're talking about, although it's been a few years since we had a TY. I seem to remember it was to stop the kick start at the end of its travel? Does it look like it's in the right place for that?

The rod definitely goes over the top of the spindle. I think it's the bit at the front you need to sort. Any photos so we can get an idea what's happening?

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Hi ! the angle bar is the kick start stop ! ALLWAYS fold up the footpeg when starting !!!!! On the one I just built for my 9 yr old I had the same concern about the brake lever and case contact ... So I bent the pedal a bit and added a peice of rubber to the pedal were it contacts. It lowered the pedal so it was easier for him to use w/riding boots on and solved the issue in my mind as I could not find any other stop for the pedal besides the case !!!

They are GREAT little bikes and seem to never lose any value either ! So they are well worth taking proper care of !!! (imho)

Have fun , Glenn

And get some adjustable pull ratio levers, so your boy can work the controls w/ a light effort !!! (great confidence builder !) I also put a throttle stop in his , as I ported and tweaked the engine when I went thru it ! It'll come out as he learns what to do !!!

post-1232-1206398463.jpg

post-1232-1206398581.jpg

Edited by axulsuv
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I`m sorry, I stated that the bar is attached to the frame, when its in fact attached to the bracket that the footpeg hangers are welded onto

The bar is a kickstart stop is it ..... The kickstart lever I bought from a yamaha specialist, and was sold as a TY80 kickstart lever, but it doesnt look quite right to me, it sort of goes up straight then bends outwards away from the casing, so sticks out when riding for little knees to hurt themselves on. Thats why I put it as far forward as possible away from possible injury (and for more travel for starting). So when kicking the bike over, the lever goes nowhere near the "stop".

I may grind the stop off then, or try and bend the brake pedal so it travels past it without snagging.

I just wrapped some tape around the brake pedal where it contacts the casing to stop any more wear on the casing, but it seems a poor design to me because of the small amount of movement of the pedal and the only thing that it rests on is the casing, thats why I thought my setup was wrong somehow, but it must be right.

Thanks for the help

PS:- Sorry I cant post any pictures as I`m not sure how to get them hosted online for me to post a link to them

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OK here goes

Didnt work :wacko:

OK here goes again...A picture of the TY rear brake lever

tybrake.jpg

You will also notice that the bolt for the footpeg is very close to the bolt for the kickstart....maybe another design fault ???

Edited by Dr Nick
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Hi Dr Nick,

as see it firstly the brake pedal was fine using the casing as a stop and they don't seem to ever cause any problems. Secondly you are right about the kickstart looking a bad fit because these are the only ones you can get for a TY80 and are sold as such but have a horrid crank at the top that makes them stick out right where your youngsters knee is, To solve this I once warmed one up and managed to get it pretty straight just like the original.

And the footrest shouldn't have a bolt through it, it should just have a 6mm pin with a very shallow head and a split pin through the bottom. Try grinding some off the bolt head that should work.

And I cant see a spring on your brake pedal this could be causing some of your adjustment problems.

see pic. :wacko:

post-997-1206551653.jpg

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.....also just to add, the problem you may find with having the kickstart so far forward is it will cause damage inside the engine because the kickstart mechanism has a stop built into it that makes a mess of the crankcase inside if it goes through too much of a rotation i.e misses the angled stop on the footrest bracket. I only know this as I once had to have one welded up! :wacko:

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Thanks for the explanation 2fargone.

I `m sorry, but when I typed the footpeg bolt was touching the kickstart bolt, what I should have typed was that it was touching the casing...I will change the bolts in the footpegs to panhead ones which are a bit smaller and made of a titanium alloy anyway I think.

After looking at your picture, then looking at my TY, I noticed that the brake lever on mine must be bent, because the actual lever part has cosmetically damaged the casing instead of the proper stop for it reaching where it should do. I`ll have to get the hammer out.

It does have a spring on the brake lever, but is attached a different way than yours, not the original one on mine i think

How did you heat up the kickstart lever....blowtorch ???

Edited by Dr Nick
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