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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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Old 26 Jun 2006
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Join Date: May 2006
Location: Los Alamos, NM, USA
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Unhappy Kick starting gone bad, need some part sources

Hi all,

Now, if you are faint of heart, you should not read this thread. I am still recovering myself!

Yesterday, I went to the nearby store on my '89 XT600W, came home, and parked it in the yard. About 4 hours later, it rained while I was out with a friend. I came home, and went to move the dampish bike. Kicked once, no choke, it sputtered, but didn't start. Turned on the choke, kicked it, and it started, and I gave it a tad bit of gas but it died. I toyed with the choke and tried and tried, but it wasn't wanting to stay running for more than a few seconds.

My friend, who has an '84, asked to give it a try. He got on, and tried starting it. I guess with his '84, he almost always has to crack open the throttle to get it to start when it's wacky like this. I never touch the throttle, as mine tends to backfire and kick back, and oh boy, it sure hurts your ankle for a bit. As such, it kicked back at him. He then remarked that my kicker goes up higher vertically than his, and kicked it again. I think it started. But, it kicked back right away and then.... CLANG!

Uh oh. The kick start lever's base was firmly embedded into the side cover, and I could see through the hole that it had planted itself into the clutch as well. Kickstarter was so well stuck in there that I had to unbolt it to get it free of the engine. Nuts!

So, as such, I'm specing out the parts I need to get it going. So far, here is the list:

Primary drive gear (really just need the clutch basket, but they are kind of attached)
Clutch hub/boss
Pressure plate
Clutch plates and friction plates
Kick starter freewheel cam
Kick starter freewheel cam stop (the metal washer thingy)
Right hand side cover

Yum! I have managed to locate mostly everything, with the exception of the metal washer thingy, I guess Yamaha no longer makes it. Whatever, I'll fab a new one. But what I am hurting for now is a primary drive gear. Yamaha wants $230 USD for it, and there are none to be found on ebay right now (as so far I am aware).

As such, does anyone have a source for a cheaper one?

Let me tell you, I'm not entirely thrilled. I really like this bike. It is my first bike, and although I have only had it for about 3 months now, I have put about 3000 miles on it. Lots of fun! I can't wait to get it running again, but stupid budgets and alll...

Thanks all for your help, and past help with the forums!

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