Ive always gone wit the EBC clutch kits, never had an issue

Maybe not what you were asking, but the 3aj uses the exact same headlight assembly as the fzr750 of the same era, which are cheap and plentiful on ebay second hand compared to 'tenere' ones and in much better condition usually. I replaced mine with one as the original 3aj one was knackered.

I find the same with mine sometimes, kickstart fitted to a 3aj, figured its just something binding when not doing the full swing correctly and needs a bit of a push to free off, as you say, it doesnt feel like its the compression stopping it. Its done that since I fitted the kickstart probably 20 ...

Like so:

If it is anything like my 3aj, there should be a hose bracket/clamp that bolts to the lower rear engine mount to hold the oil line away from the chain run. It runs close to the chain and front sprocket, but the bracket prevents it from contacting.

Thanks, I have one of these in my 3aj, I dont remember any fitment issues, but Im going to check it now.

He could have at least given it a wash first.

I seem to remember them having some carb issues when they took it to Sandraiders, but I'd expect he'd have had it sorted by a professional garage looking at the standard of his other vehicles.

Im fairly sure the headers are all pretty similar across the years, the stainless one I got for my 3aj was sold as 1987-2003 I think, one of those generic no name stainless headers you see on ebay for the xt600, it fit fine.

My Arrow exhuast came from Italy, seems to be a lottery as to whether ...

I used a big hydraulic press at a mates house to swap the gear, make sure you measure the clearance between 5th gear and the one next to it before you press it off and press the new one on to the same clearance, it was like 0.5mm or something. Otherwise its pretty straight forward.

The new Yamaha ...

Oh no, that 5th gear is goosed, looks like mine did. You can still get them new from Yamaha, at least you could last year, I got mine through Fowlers Parts in Bristol.

Id check the oil pump for damage too as the finer bits of gear which will get past the strainer did some damage to my oil pump ...