can I fit a kickstart to an XT 600 E? - Page 2

**Tenere Tom** · #16 27 Mar 2009

If you are a 9 stone weakling then you might struggle - most XT riders are big blokes who can kick over a 600!!!

The de-compressor is just there to make it a bit easier, it's not essential.

**bruken** · #17 28 Mar 2009

I put a kickstart into my 3AJ. It's easy enough so long as you dont do something stupid and break the clutch boss..... DONT ASK ME ALRIGHT!!!!... and I fitted a decomp. cable. Easy enough that one, pull out a welch plug and insert the cam. Total cost, £20 on ebay for the gearing. £19 on ebay for the kickstart. £75 !"£$%^&* quid from Yammie dealer for efffffing clutch boss plus a further £30 odd for the decompression cable and a cam.

Now I can kick the recaltriciant old bat to life after forgetting the lights on after a fag stop. By god I wish I still had my GS

**carwyn** · #18 28 Mar 2009

bruken, which parts did you actually buy? (forgeting the clutch boss

)

An earlier casing? and??

**Lamin Sambou** · #19 28 Mar 2009

Quote:

Originally Posted by carwyn

which parts ??

bit more info here:- www.xt600.de xt600 xt600e Tenere Ténéré - XT 600 von Yamaha

if the link goes to main index click on XT Werkstatt

then get translating

**bruken** · #20 28 Mar 2009

Quote:

Originally Posted by carwyn

bruken, which parts did you actually buy? (forgeting the clutch boss

)

An earlier casing? and??

I didn't need a new casing. Mine just had a plastic welch plug that I popped out.

On ebay I bought from a engine being broken up the entire geared assembly and from the dealer the oil ring

I then had to search about for a kick start lever and got one off ebay as well.

The decomp cable was a bit of a pig tbh, but for the 3AJ it turns out the TT600 cable will work fine after increasing the diameter of the crank cover hole it fits in. The cam was bought from the dealer. All I had to do there was pop another plastic welch plug out the head /tappet cover and I made a crude cable stop for the head end.

**bruken** · #21 28 Mar 2009

Mine still had legacy plastics etc. Yamaha seems to use the same engine in a variety of configurations. Even the decomp cable plastic cover was present.

**carwyn** · #22 28 Mar 2009

...so what motor do I need to get the bits from?

I don't understand the 3aj referance people make. All I know is that mine is a 1990 xt 600 e, what would an xt motor with a kick start be called?

BTW mine seems to have just a "bung" where the new shaft will be going and would it be impossible to kick over without the decompresser? I'm a big chap you know

Here's the rtranslated page from the link earlier....

Installation of a kick starter in the XT 600 E

Basics:
Who once with an empty battery and dead engine in the pampas has confessed that it will probably already have missed the good old kick starter!
In principle, however, the retrofitting of all e-models, making a distinction must be between 90-95 years of construction and thereafter.

XT 600 E Bj 90-95
Here is the retrofit is relatively easy since both the right side cover and right crankcase half of all physical conditions hold.

Needed are:

Complete kick starter unit (lever, shaft, with all parts aufmontierten)
Retaining bolts Kickstarterrückholfeder
Stop plate (2)
Kick Starter to Intermediate gearbox output shaft (between the kick starter and the gearbox input shaft)
Guide ring for kick-off spring (on the right side cover on the shaft bore)
Simmerring kickstarter shaft (in the right side cover)
Simmerring Dekowelle (in right side cover)
Complete Dekompressionseinrichtung (shaft / lever / spring bottom, decorative bowden cable, shaft / lever / spring above)
Retaining plate / thrust for Dekozug (at the valve cover)
Locking f. Dekowelle top (if not already installed)
Simmerring (in valve cover)
Right side cover gasket
Sicherunsblech (tooth wheel) f. clutch basket holding parent
Picture prepared for implantation of the engine. The Intermediate is already set up the left side of the Intermediate recognizes the hole for the Haltebozen the spring.
Before the engine (from left). Kickstarter shaft complete, stop plates, blind stopper with holding plate (waste).

Where possible, for cost reasons to second-hand parts should be used. Available from broken engines or e.g. at Paul's Enduro-Keller, Munich or other slaughterhouses.

The steps:
All the screws with Loctite medium firmly secure! When mounting a torque wrench to use, especially for the M6 screws!

Drain off oil or machine on the left side *
Right side cover dismantle old gasket residue removal *
Dismantle the clutch, it necessarily appropriate to use clutch basket holder *
Blind plug on the right side cover on the shaft bore for the kickstarter remove (not 3TB from 95)
Blind stopper with holding plate in the right half of housing on the gearbox output shaft Dismantle
Stop plate (2 pieces) instead of just dismantle retaining plate mounted
Intermediate mount *
Retaining bolts for Kickstarterrückholfeder in hole in right housing half pressing. Regard! If the bolts are not pushed in far enough, the page does not plan to cover the housing sealing surface! If the screws are tightened, the lid is tense and a tear!
Proper position of the attack on the kick starter shaft review (grains shock!) *
Kickstarter shaft *
Kickstart spring preload under mount *
Dekowelle assemble
Clutch assembly, while the same game of Ausrückhebels control *
Simmer rings kickstarter shaft and assemble Dekowelle
Guide ring for return on kickstarter shaft hole in the side cover assembly
Gasket on the right housing half auflegen
2 passport sleeves note!
Side mounted lid (to make sure that the lids really plan attached, otherwise bolts holding the kick-off after spring set!) *
Kick starter lever mount
Lever mounted on Dekowelle
Dekozug mount
Lid on Dekowelle assemble
On blind plug valve cover front right (right outlet) Dismantle
Locking in the valve cover on shaft bore unscrew
Simmerring assemble
Dekowelle use spring mount
Shaft with Locking secure
Retaining plate / thrust for Dekozug assemble
Dekozug assemble
Game / Dekozug (about 3 mm) for combustion OT set (Attention! Piston is only every 2nd revolution in combustion OT) *
* Detailed explanations are at the repair manual!

XT 600 E ab Bj 95
Here is a modified Yamaha right side cover installed (picture), because the clutch actuation to the right side was relocated. The new lid has no holes for shaft kickstarter shaft and Dekowelle more. On the automatic decompression must therefore unfortunately be waived.
Here is an image with a new (3TB) and old (1VJ) side cover. In 3TB cover has already led to the ring spring mounted.
In addition to the o.g. Steps are the following work to:

Manufacture of the shaft bore (20 mm) in the right side cover and the manufacture of the seat for the Simmerring (30 x 8 mm) (Figure).
Now, hardly anyone has a suitable milling or drilling machine stand available from the milling tools apart. It helps only in the course of the workshop (mechanical or engine repair businesses, yellow pages). The cost of this work should be under 100 DM lie.
Assembling a Dekohebels end on the left handlebar and the relocation of (records) bowden cable.
As Dekohebel can use a bicycle brake lever or a lever of models that are equipped with a manual Dekompressionseinrichtung have (XT / SR 500). The handling of the manual decompression is unproblematic

and my XT,

http://i142.photobucket.com/albums/r...s/DSC00094.jpg

Cheers

Carwyn

**bruken** · #23 30 Mar 2009

tbh I believe any kickstarter gearing from any of the pre '90 XT 600's will fit. Yes there were modifications made but the engine design and layout is all pretty standard. Somebody say otherwise if I am wrong.

(The 3AJ was the last of the aircooled XT 600 Tenere variants and did not come with a kick start. They were manufactured between 88 and 90 before the 660 was released.)

Yes... YOU could kickstart it, it's not that hard to do...BUT 2things will eventually happen. Because the shaft of the kickstart gearing whatever the hell it's called does not rest within a bearing where it exits the crank case cover, only the oposite end, the extra force required will place undue stress on the end bearing and will certainly cause the oil seal which is all that supports the shaft on the crank cover end, to have a remarkable short life span. And second, you will break the kickstart lever.......oh yes. They are only cast iron and ...... look on ebay, they sell like hot cakes. Now you know why. Get a decomp cable and cam if you plan to regularly kickstart.

**Tenere Tom** · #24 30 Mar 2009

If you are only using it for those times the battery isn't up to it - which shouldn't be often you should be OK.

The bit's are still available if anyone wants to make a sensible offer however the kickstart lever has since been sold.

**bacardi23** · #25 18 Apr 2009

You guys should start learning how to use the SEARCH feature on here... YES it sometimes is a pain in the bozzum!

I've made a complete guide for my 1990 XT600E on this question you are asking AGAIN! I even put the OEM part numbers that you need WITH the parts diagrams... just search a little will ya?! lol

And yes, It's damn easy to fit a kickstart on the XT600E as long as you have that little hole with that little plastic plug plugged in there..

on thing is important: DO NOT FORGET to get the weird shaped reinforcement "spacer" that fits on the inside of the crankcase where the kickstart shaft goes through! it is major important!!!!

Vando

**bacardi23** · #26 21 Apr 2009

No one posted after that last post of mine so here ya go!

It's easy to fit the kickstart on the XT600E and it was the first engine work I'd done on my 1990 XT600E.

Check this 1989 XT600 microfiche that I guided myself on...

here are the parts I fitted on mine: Yamaha of Troy

On the "Crankcase cover" page you need to get part 28
On the "Starter" page you need to get all those parts except the for the parts form 27 to 34.....

A good thing you can do is search for a kickstart shaft on eBay and get just these parts from the "Starter" page:

9,10,11,12,13,14,15,16,17,18,19 AND get a complete kickstart+boss kick crank....(I think I got my kickstart+boss kick crack from a XJ 650)

That setup doesn't include decompressor! but if ya want decompressor, just ask...

Vando

If you want to put a manual decompressor just read the rest here:
http://www.horizonsunlimited.com/hub...ck-start-30064

**Tenere Tom** · #27 21 Apr 2009

I wish it was as easy to fit a starter to a kick only engine

Electric starters are for girls anyway

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