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Yamaha Tech Originally the Yamaha XT600 Tech Forum, due to demand it now includes all Yamaha's technical / mechanical / repair / preparation questions.
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  #1  
Old 8 Oct 2012
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fitting a kickstart to 600e

So I have all the bits left over from an old kickstart engine and am going to see if i can fit the kickstart to my 2002 600e.....there is a plastic bung where the kickstart should be on the casing and was wondering if anyone has experience fitting one...?
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Old 8 Oct 2012
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I recall this was the subject of a lengthy thread some time ago. Perhaps a search of the forum may prove fruitful. Good luck.
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Old 9 Oct 2012
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Kenny, be advised before you start tearing down the bike.
If you have the 2002 XT600E version that still has the the clutch cable on the left side of the motor you're good to go! This version was sold alot in Aussie!

If you have the version with the clutch cable on the right handside of the engine I suggest you stop thinking about doing that change.
The right handside engine cover has to be machined in order for the the kickstart to be fitted!
This is a very precise job as everything has to be perfect in alignment!



Vando
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Old 9 Oct 2012
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Awesome...clutch cable is on the left.....
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Old 10 Oct 2012
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Forget it!

With respect, why would you waste time and money on such a thing?

Unless you are an egineer out to prove something (or show off your skills) then find something else to spend your hard earned money on...

Don't forget that Yamaha spent millions on design and research. Best let them decide what's safe and what's not.

The leccy start on the XT6E has never let me down..... (neither has the battery come to think of it).

Stay safe.
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Old 10 Oct 2012
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Quote:
Originally Posted by pusser65 View Post
I recall this was the subject of a lengthy thread some time ago. Perhaps a search of the forum may prove fruitful. Good luck.
This one maybe!

http://www.horizonsunlimited.com/hub...start-xt-41758
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Old 10 Oct 2012
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Quote:
Originally Posted by kentfallen View Post
With respect, why would you waste time and money on such a thing?
Because he wants to.


Quote:
Originally Posted by kentfallen View Post
Unless you are an egineer out to prove something (or show off your skills) then find something else to spend your hard earned money on...
He wants to spend his money on this, good on him, he earned it.

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Originally Posted by kentfallen View Post
Don't forget that Yamaha spent millions on design and research. Best let them decide what's safe and what's not.
No, let the customer decide whats best, they just left out the kickstarter to save a few bucks.

Mezo.
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Old 11 Oct 2012
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Here is the link for the thread I posted on here to make Kickstart conversion:

http://www.horizonsunlimited.com/hub...ck-start-30064

I've just updated the parts links on the first page.

On the last post of the thread, on page 2, I even tell you how you should properly kickstart the bike without the auto-decompression assembly.



Good luck!
Vando
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Old 11 Oct 2012
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Actually I am an aircraft engineer so I have the skill anfd I have the parts left over from a previous engine.....I do it just for fun....you never know eh.....
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Old 11 Oct 2012
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Ouch!

Well, it's a pretty straight forward job to be done if you have the right tools.

One advise, either you use the Yamaha clutch tool to secure the clutch basket in order to remove the clutch so you can fit the kick idle gear OR you have to use a pneumatic gun with the right socket and grab the clutch basket with a cloth so it won't spin!

When I fitted the kickstart on my XT I made a bracket to hold on the clutch plate's bolt mountings and I broke two of them without applying barely any tension...


Vando
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Old 11 Oct 2012
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A child could do the job, its only a matter of following instructions.

I remember as an eleven year old i blew my Honda Red Rocket to bits, my kid brother (seven) sat down & pulled it to bits, repaired everything & i put it back in the frame (he was to weak to lift it) & first kick it started.

Have a go i say, its not rocket science.

Mezo.
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Old 11 Oct 2012
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Yeah....I know about breaking clutch baskets ha ha ...now I use the rattle gun.....will see how it goes....finished fixing my 86 tenere and will take it for a wof(mot) tomorrow and start running it in ....so much more grunt than my xt that the xt might get left in the shed ( well not the shed really as since the earthquake I have no garage any more....just a broken house ha ha)
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