3AJ Kickstart Conversion

**bolla** · #1 16 Mar 2006

Hi
I would like to put a kickstart on my xt600 3AJ. I am sure there was a link to a shop which supplied all the parts needed to do this but cant find the link now. I think the shop was in Holland. Does any one know where I can get the parts needed would also like to fit a decompresser as well.
Thanks

**El Aleman - Jens** · #2 16 Mar 2006

Hi, I did the same. Check out the german ebay, I think you will find everything within a couple of weeks. Or check www.tenere.de perhaps you get there the information

Good luck - Jens

**Mark** · #3 16 Mar 2006

Hi Bolla

I bought second hand parts for our conversions, and didn't bother with the decompressor parts. I had no problem kicking it over without it. I don’ think you need it if its just for a back-up.
The new parts that you will require are a clutch cover gasket and the oil seal that the shaft passes through, that replaces the plastic plug that is currently fitted.

It’s probably wise to also fit a new return spring rather than risk the old one snap.
Also, the thin washer innermost on the shaft will is very likely not to come out with the shaft assembly when the breaker removes it, but stick to the engine case, so it's worth ordering that too.

**bolla** · #4 2 Dec 2006

Hi
Am trying to fit a kickstart to my 3AJ
I bought a kickstart shaft for a XT-TT from e bay.
Tried to fit this today with no luck.
Had a look at the manual after putting bike back together and it shows a kick start idle gear.
Do I also need to buy a kickstart idle gear or will this be on my bike already?

I know I should have looked at the manual before taking side casing off>
Thanks

**aukeboss** · #5 4 Dec 2006

With that you mean the gearwheel that engages on one side on the clutch hub and the other on the kickstartshaft? Yes, obviously you need it to transfer your kick to the clutch and then onwards to the crankshaft.
I think such a gearwheel would not even be too expensie new. The gearbox shaft that it should be installed on already has two circlips. Just remove the little bush that's in place of the idler gear. You need two rings, one on each side of the gear.
Warning: at the location where the kickstartshaft goes through the casing you need a reinforcement ring. And so on.
Best to take a microfiche from a bike without kickstart and one with kickstart, and compare the the parts and then decide which you need and which you don't.

Auke