The kick starter and the 3AJ clutch cover

[karaz]

Hello,
so today I wanted to start with my little project.
I have already bought the neccessary parts to add a kickstarter on my 3AJ.
Today I drained the oil and took of the clutch cover and what I found pretty much ruined my day as I probably wasted around 200€.
Turns out these rubber plugs for the kick starter and the decompression lever aren't actually plugs but mere decor.
As you can see I scraped away bits of the rubber and under that there is metal, no hole in sight.



And here's the other side:



Is there a way to screw these off or something? Does it really have to be drilled?
I would also have to mill pockets for the rubber seals... :(
I made some research and apparently drilling was only ever neccessary on newer XT600 models.
Should I just buy a 1VJ clutch cover? Do these fit on 3AJ engines from 1991?

regards

[jibber]

That is strange, usually just plugs (sure its 3AJ?), 1 VJ cover wont be any good, you would lose your external oil feed, maybe another 3AJ cover??

[karaz]

Well one of the previous owners might have replaced the cover. Are they even interchangeable with those of other XTs?
Now that you mention it. My bike's fuel capacity is only 17 liters as opposed to the claimed 23. But that's a different topic, heh.
Anyway, the bike is definately a 3AJ.
Yeah I guess I will have to look for another 3AJ cover with holes.

[motorang]

I am running a 1VJ cover on my 3AJ engine. No problems there, just bolt-on.
So I should have a leftover 3AJ cover which I do not need.
Not sure when I will find it, but can give it a go on the weekend.

Andy

[karaz]

Hey Andy,
thanks for the offer but I'm already in contact with motoritz regarding the cover.
Maybe he can even get me the kickstarter shim that's missing for me.

On horizons unlimited I read a post saying that it's just an aluminium plug covering the holes and that it can be forced out.
I don't have the neccessary tools for that and I don't want to risk ruining a perfectly fine cover but I figured someone might try?
http://www.horizonsunlimited.com/hubb/y ... xt-41758-3

Edit:
I punched out both of those plugs yesterday, looking good so far.