156 replies to this topic

[Kenzo TT Addict]

my solution wus to purchase a 400 EXC

[HeadTrauma Get Help Now]

You're a turncoat, so we don't listen to you anymore.

[ThumpNRed TT Titanium Member]

Kenzo said:

my solution wus to purchase a 400 EXC

The shortcut, easy way... Keep tormenting the lunatics and we'll evict you from the asylum

[Kenzo TT Addict]

ThumpNRed said:

The shortcut, easy way... Keep tormenting the lunatics and we'll evict you from the asylum

...same HP as the XR and only weighs 260lbs!

...did i mention it has a 6th gear???

[ThumpNRed TT Titanium Member]

Kenzo said:

...same HP as the XR and only weighs 260lbs!

...did i mention it has a 6th gear???

You've been warned... keep agitating the "residents"
'sides... I live in my own reality... don't try to confuse me with numbers!
I like my piggie, even though she's a tad overweight and handles a bit like a angry rhino. Sounds like my kinda girl! Who wants to date a prom queen that can cook?! That'd be too easy! Go ahead though... keep dancin with yer prom queen. One day when she leaves you walking... you'll be kissin a pig

[HeadTrauma Get Help Now]

Kenzo said:

...did i mention it has a 6th gear???

'Cause it has no torque.

[Kenzo TT Addict]

HeadTrauma said:

'Cause it has no torque.

HAHAHAhahahaaaa...   ...yeah right!

i'll leave u to ur lala-land

[ThumpNRed TT Titanium Member]

Kenzo said:

HAHAHAhahahaaaa...   ...yeah right!

i'll leave u to ur lala-land

Torque?! My flywheel weighs almost as much as your bike! Course she's got some torque!

[pablo83 TT Silver Member]

I'm reassebling and NX650 engine after installing a kickstart.  When I spin the crank forward the kickstart gears constantly spin and cause the one-way engagment portion of the kickstart to click constantly.  Is the systemp supposed to completely disengauge when the engine is running?  Also when I spin the engine backwards it engages the kickstart.  I know you aren't supposed to spin the engine backwards, but on occation I've been denied on some stupid steep slope and used the clutch to help control the bike while trying to back it down.  Is this no longer an option with the kickstart installed?

[jscompto TT Member]

Here are some pictures of what I did when I added a kickstart to my XR650L:

Bare case with no gears:


Close-up of where the gears go:


Kickstart spindle assembly:


Fitting the assembly in the case:


Make sure you line up these marks on the spindle parts!!:


Kickstart spindle assembly installed in case:


Idler gear and bushing are installed on the end of the countershaft like this:


Then all you have to do is slap the cover on and put the kickstarter arm on the outside of the clutch cover and you're ready to go!

[HeadTrauma Get Help Now]

pablo83 said:

1.) Is the systemp supposed to completely disengauge when the engine is running?

2.) Also when I spin the engine backwards it engages the kickstart.  I know you aren't supposed to spin the engine backwards, but on occation I've been denied on some stupid steep slope and used the clutch to help control the bike while trying to back it down.  Is this no longer an option with the kickstart installed?

1.) No, the ratcheting mechanism just freewheels. Now that I think about it, that could be some of the "clicking" people often hear when a cold engine is started.

2.) Using jscompto's photos, there is a pawl just to the right of the gear here:

http://i261.photobuc...ld/IMG_1107.jpg

That engages the retaining strap shown bottom left here:

http://i261.photobuc...ld/IMG_1106.jpg

That disengages the kickstarter if it is at the returned position AND the engine kicks backward.

[ThumpNRed TT Titanium Member]

You all will get a kick (pun intended) out of this.
I read Pablo's post and thought... hmmm... that must suck. Then I read JS' reply and... !!!! Mine doesn't look like that! Something's missing!!!!


Out to the garage to rummage through the bag of leftover junk from the XR600R bottom end that I scavenged the tranny and kick mechanism out of. Much to my horror...


There were several "odds and ends" included in the box with the bottom end. I knew what 99.9% of them were... case screws and other crap I didn't need. I completely dismissed the :censored:ed spring.

I guess when the break-in oil gets dumped this weekend, the cover comes off as well.

Strangely enough, the kickstart gear doesn't make noise when mine is running. HT... think it will do damage to run it for a few days to get the rings seated?

This is too bizarre to make up!

[HeadTrauma Get Help Now]

That spring is there to push the ratchet teeth together. I don't think it will hurt anything to run without it for a while, but it may cause the teeth to not engage fully when kicking and could conceivably cause damage(to itself or you) if they slip.

[ThumpNRed TT Titanium Member]

HeadTrauma said:

That spring is there to push the ratchet teeth together. I don't think it will hurt anything to run without it for a while, but it may cause the teeth to not engage fully when kicking and could conceivably cause damage(to itself or you) if they slip.

I have been using the button until I get a decomp cable, so no worries there.
Runs like a raped ape though!

[jscompto TT Member]

mine does make the noise...constantly...Its something I can live with, but it sure is annoying. I was beginning to wonder if I had forgot something when I installed it. Another thing too...once the engine is running, the kickstart lever goes straight down and stays there. I use a zip tie to keep it in place. Anything I can do to fix that??

[ThumpNRed TT Titanium Member]

jscompto said:

mine does make the noise...constantly...Its something I can live with, but it sure is annoying. I was beginning to wonder if I had forgot something when I installed it. Another thing too...once the engine is running, the kickstart lever goes straight down and stays there. I use a zip tie to keep it in place. Anything I can do to fix that??

I'm not the expert (clearly:smirk:), but it sounds like you didn't preload the return spring. When you first drop the mechanism in, you have to catch the spring in the hole in the case and wind the shaft about a full rotation(counterclockwise... Clymer manual has it WRONG) so the stop on the back of the gear clears the stop that you bolted to the case. Once the stop is clear, you push the end of the shaft into the case. This preloads the return spring. We may be doing the same thing this weekend...

[jscompto TT Member]

HAHA, yea no doubt! I'll look into it and probably be changing oil and filter again anyways. So, my clymer manual is wrong then...hmmm. Mine didn't mention anything about hooking the spring and pre-loading it if I can remember right. Thanks for the details I'll let you know what I end up figuring out.

[pablo83 TT Silver Member]

where's the hole that the spring is supposed to go in?

[clc3251 TT Bronze Member]

ThumpNRed said:

I have been using the button until I get a decomp cable, so no worries there.
Runs like a raped ape though!
HeadTrauma  View Post
That spring is there to push the ratchet teeth together. I don't think it will hurt anything to run without it for a while, but it may cause the teeth to not engage fully when kicking and could conceivably cause damage(to itself or you) if they slip.

I believe that that spring is solely for the decomp cam and should not affect the operation of the kickstart gears.  I eliminated the decomp parts on the kickstart spindle, including that spring, and my bike kicks over very easily without it and no gears slip.  I still have the auto-decomp on the cam, but no other manual decomp.

[ThumpNRed TT Titanium Member]

pablo83 said:

where's the hole that the spring is supposed to go in?

The wide slot at about two o'clock from the hole where the spindle goes. Right behind the follower wheel for the shifter mechanism.