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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 11 Oct 2006
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Question Kick starter on 3AJ??

Hi all....
I have been having starting troubles with my '89 3aj... The bike only has an electric starter and that has got stuck brushes for the third time in as many months.... Have had it refurbished but that does'nt seem to have helped, Solonoid and Ignition circuit seem fine,anyone know the step by step process of checking the whole circuit...?

The bike does push start,with a bit of PT....Running out of eager Mates!!! What I would like to know is it possible to Transplant the side cover,kicker and decompression bits from a 1vj tenere to my bike....?(as a back up) What about the internals like Ildle gears and the like! My cover also appears a bit wider,so will the clutch assembly still fit? I have looked at a microfiche of the parts and it looks fairly intricate!!

Any advice would be Gratefull!

Thanx Bryan
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Old 11 Oct 2006
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hiya i have been looking into this i think your case has the hole for the kick start in it but it is just blanked off inside there are the holes for the bearings and shafts for the idler gear and kick start mechanism from what i could make out you could have both there at the same time and use whichever. hopefully this is the case but someone may know for sure.
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Old 11 Oct 2006
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Lightbulb Not sure!

Hi xtmito
I did see the blanks,but what concerns me is that there are 2 or 3 circlips that hold the idle gears in place,and I think the standard shaft does not allow for this...I Stand corrected though...?

Any Thoughts?
Bryan
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  #4  
Old 12 Oct 2006
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I have done it

Hi,

I have fitted a kick start th both a 3AJ and a 3TB, it's straight forward enough.

I didn't bother with the decompressor part and have no trouble kicking them over without (but I am 6 foot 4)

I ordered all the parts second hand except for the oil seal that the shaft passes through once the blanking plug had been pushed through. I han no issues with shafts not having circlip grooves etc.

Look through the old posts for more info

Mark
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Old 14 Oct 2006
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Thumbs up No probs

Don't forgett the little case reinforcement where kick shaft goes out, it protects the aluminium case.
For your e start problems, it could be as simple as a badly tightened battery cable or oxyde between cable and battery leads, or just a dead batttery.
Also check black - cable from regulator to chassi, WD40 and retight.
Check the red black cables on the device front battery, they can loosen.

I wouldlike to add a tip concerning dead batterys, cause generally what do we all do when it can't hold the charge or some dirt inside creates nasty shortcuts= we throw it away and buy a new one..logic I guess!
But there truely is a way to ressurect a dead battery,
here's how you do it:

1 Make sure you don't smoke or stand near something burning; explosion of battery gas is possible.

2 Use a breath mask and gloves if you have.

3 Unplug the cells of the battery, poor out all of the acid with all of the lead oxyde thru a coffea filter into a plastic bottle.

4 Fill up to max level every compartement with demineralised water.

5 Shake like a vodka/martini to clean up, poor out water and dirt again.

6 You can now fill with water again but firstly all of the acid you filtered, you will then put the battery on charge for 24 hours..top up when water is boiling away.

7 There you are ready for one more year of e-starting.


Matt

Last edited by Matt595; 14 Oct 2006 at 00:25.
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