XJ 1100 kick start

[XJkid]

Has anyone installed a kick start lever on an '82 Maxim 1100? I am going to tear down my motor to replace a rod and would like to enable the kick start for a back up in case my starter clutch goes out.

[crazy steve]

Yep, it can be done if you're splitting the cases. You'll need most of the parts listed here (select and click on 'kickstarter')....http://www.benefiscal.co.uk/ps.php .... which can be gotten out of any '78-79 XS11 motor....

[cywelchjr]

The only issue as I recall, is that the kick start goes through most of the same stuff as the starter. That said, the primary clutch portion can indeed fail and leave the kick starter functional as Randy found. That doesn't however make it fun to need to kick start it.

You do need to split the cases for sure on the XJ cause there are a couple of parts on the transmission shafts that have to be added to make it work that were no longer included after 1980. 1980 engines need only the parts in the clutch pack chamber side of the system added to added to make it work, while later engines need everything.

['OlGuiltyBoy]

The only issue as I recall, is that the kick start goes through most of the same stuff as the starter. That said, the primary clutch portion can indeed fail and leave the kick starter functional as Randy found. That doesn't however make it fun to need to kick start it.

You do need to split the cases for sure on the XJ cause there are a couple of parts on the transmission shafts that have to be added to make it work that were no longer included after 1980. 1980 engines need only the parts in the clutch pack chamber side of the system added to added to make it work, while later engines need everything.

So what about the XS (1980), would I have to crack the case for that? I noticed it just has a plug there, have yet to open it up and see whats inside. Been working on everything else, but I keep glancing at it while I'm out there ...

[natemoen]

So what about the XS (1980), would I have to crack the case for that? I noticed it just has a plug there, have yet to open it up and see whats inside. Been working on everything else, but I keep glancing at it while I'm out there ...

I thinly the '80 engines are sort of like the '80 carbs, some have the internal parts some don't...

['OlGuiltyBoy]

I thinly the '80 engines are sort of like the '80 carbs, some have the internal parts some don't...

So I just have to pull that plug I've been staring at and see if there are some gears in there ....

[crazy steve]

So I just have to pull that plug I've been staring at and see if there are some gears in there ....

No, there's a bit more to it....

There's at least one gear and a ratchet mechanism inside the cases (not just behind the clutch cover) that may or may not be missing on your '80 besides the 'stuff' that's in the clutch cover. Some early-80 motors have the parts, the later ones don't; and unfortunately, no one has determined exactly when the change occurred (serial number, date of manufacture). None of the '81/82 motors have the parts...

['OlGuiltyBoy]

No, there's a bit more to it....

There's at least one gear and a ratchet mechanism inside the cases (not just behind the clutch cover) that may or may not be missing on your '80 besides the 'stuff' that's in the clutch cover. Some early-80 motors have the parts, the later ones don't; and unfortunately, no one has determined exactly when the change occurred (serial number, date of manufacture). None of the '81/82 motors have the parts...

hmmmm... i'll save this as my last project then. seems more trouble than what its worth, im not ready to crack open the engine yet. it was just redone ... (or so says the po)

[BA80]

You can see if the parts are in there if you just pull off the clutch cover. I wouldn't take the plug out you'll probably end up with a leaky clutch cover.

[cywelchjr]

Yes, at Greg says you can tell from pulling the clutch cover if you need to go further. AFAIK, most 80 engines have the parts that require splitting the cases to add the kick start, so adding the kick start in MOST cases with an 80 engine involves only pulling the clutch cover and clutch pack and adding the parts and then reassembling and then replacing the broken star plate you broke putting the clutch pack back in (only partly joking, be very very careful with that star plate, if you do everything just right it goes together just fine, do it slightly wrong and it breaks) and putting the cover back on with the kick start parts installed in it and putting an 850 lever on it (said to be the best fit) if you want to keep a full time lever on there.

[cywelchjr]

hmmmm... i'll save this as my last project then. seems more trouble than what its worth, im not ready to crack open the engine yet. it was just redone ... (or so says the po)

IMHO, it IS more trouble than it's worth. The one time I've not been able to electric start it (ok 3) two times I was able to easily get a jump start and get home on that, and the other I was able to bump start it and get home on that.

Oh wait, it was 4, and the other time was because of a dead charging system and it died on the side of the road 3 blocks from home. SWMBO came over and we hooked the car up with jumper cables, let it sit idling for about 15 minutes with gave me enough to start it and ride home. I put it on the charger and luckily the replacement rect/reg had arrived that afternoon so I replaced it and that was the last time I had a problem till the battery died about a year later.

['OlGuiltyBoy]

Cool, maybe I'll take a look sooner than later. I actually want to see how the clutch is looking anyway. Its not going to be ready for the street til next season anyway ... might as well

[cywelchjr]

Very few find the clutch to need anything more than new quality clutch springs. So while it can't hurt to check everything, the primary thing to watch for is the length of the springs in relation to spec. But, 30 year old springs are unlikely to be in spec anymore, so you will likely need to replace them, but they are pretty cheap, like way less than $20 cheap no matter what ones you get, with some like less than $10 for a set. If worried one member also did a set that replaced the frictions and steels with new and the steels were a little thinner so you got one more steel and friction for the same thickness which made the clutch grab tighter and more securely.

['OlGuiltyBoy]

Very few find the clutch to need anything more than new quality clutch springs. So while it can't hurt to check everything, the primary thing to watch for is the length of the springs in relation to spec. But, 30 year old springs are unlikely to be in spec anymore, so you will likely need to replace them, but they are pretty cheap, like way less than $20 cheap no matter what ones you get, with some like less than $10 for a set. If worried one member also did a set that replaced the frictions and steels with new and the steels were a little thinner so you got one more steel and friction for the same thickness which made the clutch grab tighter and more securely.

Yea, there's a Family owned Yamaha place across from my job. I'll stop by there and get them to order up everything on the clutch for me.

[petejw]

hi OlGuiltyBoy
if u pull the oil filler plug out u can see inside the engine
if the internal gears are fitted or not with out
having to remove the clutch cover.
if you can see the gear u wont need to split the cases
to put the rest of the stuff required for the kick start.
if the internals arent fitted ull see a hole where the oil flows thru,
youll have to split the cases,
look inside both bikes and youll see the differences.