XT600e with kickstart...doable?
 

I have an XT600e (2000) with electric start only and would like to convert the bottom end to a kickstart as well, has anyone done it and how much has to be done to the crankcases?

This is easisly done in 30 minutes if you have all the bits.

You will need a kick start mechanism, kick start lever and a cover off a kicker XT600 (and a gasket if you can't re-use the old one).

The question has been asked here many times (look for old threads).

I may have all the bits you need (except the kick start lever).
Offers invited via PM

Original cover can easily be used
 

Hi Captain,

You don't need to change the right crank case cover on your year of bike, there is a plastic plug that can just be pushed out to reveal the hole for the kick-start shaft to pass through. There is a strengthening plate that idealy should be fitted into this hole.

Search the earlier threads for it's number and lists of parts required. I would allow a day to do it, remembering that you may need to loosen the exhaust to allow you to remove the oil link pipe that goes between the top crank case and the right cover, plus carefully scrapping the old gasket off takes ages.

Good luck

Mark

hmm if my brain still works, 2000 model has clutch on right side, and no hole (closed by plastic)

so you can't open the hole, nor replace the right side cover with a previous model one.

What???

Is the clutch on the left on yours??? It's a one off if it is!!!

The clutch covers are all the same except for the hole (and colour).

Sorry did not explain properly...

starting from late models clutch CABLE is on the right side. So you can't use a previous model right cover.
And if i'm remembering correctly, on these late models (DJ02) the right carter cover has no plastic cover where originally was kickstart shaft.

Why not?

because if you take a 1984, or 1988, or 1990 right cover, you will not have the hole for the clutch shaft on top of it... on all these the clutch shaft\lever\cable are on the left side. Starting from 1995 (or later maybe) clutch shaft\lever\cable was moved on the right. I'm not 100%sure but think that from same time the hole for kickshaft was canceled at the same time (no plastic plug). I can be wrong on this last thing, wait for someone that has this engine to confirm or not.

I have a 2001 XT600E. There is no hole in the right hand cover but there is a protrusion under which is cast "Kick Starter". I have not had the cover off yet but I would suspect that on the inside it is strengthened so that a hole could be drilled to facilitate the retrofitting of a kick start.

I did my 1991 600E
 

Hi,

The change happened after 1991, not sure exactly when, but my 1991 600E still had the hole plugged and was readily converted.

If the clutch cable comes into the left side of the top of the crankcase you are OK. When it moved to the right side of the upper crank case the right side cover was changed, making fitting a kick start much more difficult, requiring machining of this case and other problems. Earlier posts give details.

Mark

See also here

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

My TTR600RE - 2004 - has L/Hand clutch cable and a kickstart grommet - so is that the same easy fit?

I converted an electric start engine to kick start without any issues.

I still don't see what the problem is.

cyberzar said it right!

up untill 1995 the XT600E had the clutch on the left engine side. After that they changed it to the right hand side.

Please note that some Australian an probably other countries have sold the "latest" XT600E with the older pre 1995 engine!


Kickstart on the XT600E that has clutch on the left has been said to be doable but I don't know anything about it as I got a 1990 XT600E.

On my 1990 I have fitted the kickstart which was very simple as long as you have all the parts and tools you need!



Vando :smartass:

Hey Tenere Tom, not everybody is as clever as you, hence the need for this forum. If people are made to feel humiliated when they ask a question then they may not bother again and the forum would be poorer as a result. I suspect there are a number of us who hesitate to ask questions because of the fear of appearing a numpty to the more experienced.

the problem is that as confirmed by pusser65 and mark, there are some version of the XT engine that DON'T HAVE A PLASTIC COVER that closes the kickstart shaft.

Can you please confirm if the engine you converted had this cover\hole or not?

Because without it you need special equipment, to make the hole in the right engine cover. As said in another post, David Lambeth can do this work, but it's not so cheap.

not sure what you mean with left hand... you must first check if you have a plastic plug where kickstart shaft should be... if the answer is YES, kickstart is easy.
If answer is NO, check if the clutch cable ends on top of RIGHT (kickstart) side engine cover. If second answer is NO you can go and buy on ebay a previos model cover, with the plastic plug to be removed or already with the seal installed.

If you have NO plastic plug, and the clutch shaft is on the right side, well unless you find somewhere a right side cover with the hole already done, your only choice is someone with the knowledge to do this hole for you.

Cheers Cyberzar - I did word my post rather poorly :nono:

My clutch cable is along the left of the bike.
The clutch casing is on the right & it DOES indeed have a plastic bung (& writing saying KICK STARTER) on it :thumbup1:

So all thats needed is the kick start mechanism complete & an actual kick start lever? And then you just "whack" it in :confused1:

SOunds too easy by half. I'm interested coz I have just got hold of an Ohlins shox and also need to tweek the clutch adjuster coz the cable is near the limit of slack adjustment - so as the clutch cover needs to come off - thought I may kill 2 x birds - 1 x stone; and all that :eek3:

U r lucky...:smartass: simply search the full list of needed parts, and when you open to change clutch, do the job. Do not forget the decompressor and all related parts.

Thanks for the info guys, I definately have the clutch cable on the right hand casing and doesn't appear to have a plastic plug, that said I do have access to a mill so it's down to wether it's easier to convert an old casing to take the clutch or convert my existing casing to take a kickstart shaft.

Tenere Tom, pm sent but your inbox appears to be full.
Dave.

Made room - send it again!!!:thumbup1: