Hot start lever TC250

Hey guys,

what does everybody do to change their hot start button on the carb? I notice Husky make a seperate hot start lever but its pretty expensive!!

I used the genuine brembo parts to use the lever on top the clutch perch. I think this is standard on the TE? Works out at half the price of the genuine husky one and look better IMO.

Looks good where did you get the parts and what did it cost i would like to do the same

I got the parts from my local bike shop. I have the part numbers for each bit if you need them. Cost me about £70 compared to the £108 for the Husky lever!

I like our Husky kit. May not look as polished as the Brembo mount, but it is MUCH more versatile, allowing it to be mounted in different locations and positions. The location of the master cylinder lever lends itself to accidental actuation from a fumbling finger during a moto, or a tree branch/limb during a woods race which could lead to disaster. I'd rather have it mounted behind the bars where the only thing that will pull it is the thumb of a rider who really meant to pull it.

please do that would be great

Maybe I guess for woods riding etc, but for racing its better.

Bear in mind that the hotstart plunger is changed as part of the TC250 carb upgrade so the genuine Husky hotstart kit is no longer recommended for the 2010 TC250.

Dave

Yes but any motocross rider with half a brain wouldnt want the hotstart as a button on the side of the carb! Its right next to the choke, and after a crash during a race, you dont wanna be pulling the choke out instead of the hot-start! The bike should come like this from the factory IMO

Yep you're right and we have asked for this from the factory. My point was that the new plunger fitted to the TC250 as an upgrade is different to the one supplied with the hot start kit so you could end up with a bike that's harder to start, which would somewhat negate the advantage of having the lever on the bars!

Dave

Heres the part numbers for the Brembo parts. You can get these at any KTM dealer.

77002047000 Hot Start Lever £7.46
(this is just the red plastic lever)

77002003000 Master Cylinder Cover £23.62
(this is the new lid which the lever attaches to. It comes with new rubber seal and the 2 little screws)

77002096000 Hot Start Cable £8.28
(as it suggests this the cable)

77031075000 Hot Start Valve/Plunger £21.35
(this is the plunger, you need this as it comes with the 90 degree part of the plunger)

All in all it cost me £60.71 which I thought was pretty good. All fits perfect and is tonnes better!

Lewis

Ah I'm with you. We fitted the Brembo parts to ours before we even rode it, so we never had any problems.

Lewis

Thats exactly what I wanted for my TC250....but I found it easier to switch to a WR125....I can't say I miss fumbling around the carb to pull that little red lever up and hope it started.

Simple fix... don't pull it all the way out. Ours works well if you only pull it about 1/2 stroke.

The problem with the standard plunger is that it was too short, so it didnt seal. The new plunger that everybody had was slightly longer so it sealed. Nothing to do with how far you pull the lever

Not to start a firestorm here, but that is wrong. I'm looking at both of mine as I type. The plungers are the same size and length when fully pushed in. When pulled out, the new plunger simply reduces the stroke length when it snaps into the engaged position (all the way out), reducing the amount of opening in the carb during hot starting... the exact same effect as not pulling the bar mount lever all the way. The pics show it. Remember, the frame of reference is the threads and not the red button.

Maybe US and UK were different? As our new plunger was longer than the old!

We used the new hot start before the bike was ridden so we never had any problems

That could be I suppose. I wonder if any of the Euro-spec members have both knobs and could compare them. Our bar mount hot start works great when you pull it about 1/2 out. I'm thinking about rigging some sort of stop on it.

Yeh that would prob work. Is yours the Genuine Husky hot start?

Yes, It's the Husky part. I'm grateful for this thread because it forced me to "engineer" a very effective "travel stop" for the lever! Whoever invented ty-raps should be Knighted in the UK and put in the Inventors Hall of Fame in the US!!!

OR - if you don't mind a little orange (nothing some emery cloth can't take care of...) this would let you keep the decompression lever on the left and add a hot start to the right -

Hot Start